Adaptive and smart materials and structures for more efficient vessels

Transcription

1 Adaptive and smart materials and structures for more efficient vessels Results of the ADAM4EVE Research Project The project has received funding from the European Union s Seventh Framework programme.

2 Adaptive and smart materials and structures for more efficient vessels Dear Reader, In recent decades, the strategy for European shipbuilders was to offer highest quality products that best fulfil the individual customer requirements. There is a variety of approaches that allow for optimising a vessel, for instance improving the hull form or introducing lightweight materials. Usually, these measures were applied in a way to optimise ship designs towards their performance and efficiency at a certain defined operational scenario. However, the environment in which a ship is used is never the same. Weather, payload, operation schedule and other parameters usually differ significantly. Therefore, a ship usually spends a significant part of its service life operating in situations other than design conditions. Hence, a penalty in terms of efficiency often has to be accepted. Having this in mind, a ship design that provides the best efficiency under a reasonably wide range of operational conditions should be considered an optimum design. The key to meet this challenge is to make use of adaptive and smart materials and structures. Windows with controllable transparency in buildings and morphing aircraft wings are examples that already exist. The strategic goal of the ADAM4EVE project was to explore the potential of adaptive materials and structures in maritime vessels. Initially, various opportunities of making ship hulls and outfitting systems more flexible were explored. Subsequently, the most promising options were taken up. A set of smart design solutions was developed that help to provide optimised properties of ship hulls and outfitting systems at varying conditions. Finally, prototypes have been built and assessed in terms of technical properties, safety issues, and economic and ecologic impact as well. The brochure at hand is intended to give an overview of the technologies, the potential fields of application, the benefits that can be expected, and the achieved maturity of each solution. I would like to take this opportunity to express my gratitude to the entire ADAM4EVE consortium for the excellent and fruitful cooperation in this project, and to the European Commission for continuously providing valuable support. Enjoy reading the brochure! Matthias Krause Center of Maritime Technologies e. V. ADAM4EVE Project Coordinator 2

3 Table of Contents Page 4 Adaptive stern flap Page 6 Adaptive damping system for thruster Page 8 Phase changing composite cargo deck Page 10 Adaptive bulbous bow Page 12 Adaptive window Page 14 Adaptive rudder-propeller Page 16 - Discovering potentials ADAM4EVE

4 Adaptive and smart materials and structures for more efficient vessels Adaptive stern flap saves fuel on RoPax vessels Varying cargo, shallow water, wind, waves and seasonal speed profiles are typical challenges in a RoPax vessel s operational profile. A conventional ship hull cannot be optimised to achieve best performance for any combination of the above variables. On the other hand, relatively small modifications of the hull form, especially at the bow or stern region, can yield improvements. ADAM4EVE foresees a pneumatically driven adaptive trim wedge. The structure can be lowered and retracted depending on the changing operational condition of the vessel. Both model tests and CFD calculations have shown significant efficiency potential under realistic operational conditions. Thanks to low installation costs, a quick return on investment (ROI) can be expected. 4

5 A model scale demonstrator has been built that features the actuation principle. Jens Heyer, Head of Projects Department, Flensburger Shiffbau-Gesellschaft, Germany Introducing innovative solutions like the adaptive stern flap gives us the opportunity to develop flexible and efficient ship designs. Tuomas Sipilä, Research Team Leader, VTT Technical Research Centre of Finland Ltd, Finland VTT performed model tests for the new concepts developed in the project. Model tests are vital in the final evaluation of the success of the new innovations. ADAM4EVE

6 Adaptive and smart materials and structures for more efficient vessels Adaptive damping system for thrusters increases comfort on cruise vessel Bow thrusters are inherently strong sources of noise and vibration. Thus, whenever noise and vibration sensitive areas are located close to thrusters in frequent operation, the implications from a comfort point of view should be considered. The most powerful thrusters have a large diameter propeller and slow rotational speed. The combinations of both parameters are higher response aboard the ship as the frequency of excitation is getting closer to the ship s first resonance frequencies. The active control system is, here, used to reduce these vibrations in areas where local modes are matched with the bow thruster excitation frequency. FEM calculations have permitted to detect a local deck resonance with a frequency close to the bow thruster blade passing frequency. 6

7 The active control system with two actuators, two feedback sensors and a fixing structure to connect it to the deck structure. Clément Lucas, Acoustics and Vibration Engineer, STX France This active control system appears as a very promising and mature solution to reduce vibration induced by bow thrusters. It is easy to install and adjust and offers large potential vibration gains for our ships. ADAM4EVE

8 Adaptive and smart materials and structures for more efficient vessels Phase changing composite cargo deck reduces energy consumption, weight and cost The new generation of refrigerated (reefer) cargo ships will exploit an innovative decks made of composite sandwich panels containing phase changing materials (PCM). PCM embedded into the panel core allows minimised heat transfer and significant cooling-energy savings. Another great advancement brought by lightweight composite panels is a significant saving in structural weight and increased cargo-carrying capacity of the reefer. Production time and costs are reduced by half thanks to simpler handling and assembling of modular sandwich decks. PCM performance testing done by Fraunhofer Institute confirmed the energy saving expectations and justified the use of PCM in marine environment. 8

9 Strength tests made by Uljanik Shipyard showed high load-carrying capability of a PCM sandwich prototype and validated its solid design. Djani Dundara, Senior Designer, Uljanik Shipyard, Croatia The customer is pleased to apply this advanced concept because the maintenance costs of composite panels are much smaller since composites do not corrode. Dr. Sc. Darko Frank, Managing Director, as2con-alveus, Croatia The concept of sandwich panels is long known to save mass and production costs. However, the prototype containing PCM is the first application case that exploits a panel s potential for thermal energy savings. ADAM4EVE

10 Adaptive and smart materials and structures for more efficient vessels Adaptive bulbous bow saves energy on Inland waterway ships In order to reduce fuel consumption, improving reducing the total ship hull resistance and finding new solutions for ship hull forms is mandatory. The bulbous bow is a usual solution for sea going ships, due to the existence of certain main operational conditions. For inland waterways ships, due to the variation of certain parameters (such as water depth, ship speed, current speed etc.) it is difficult to define a single bulb, able to cope with the variation of so many parameters. The investigation of an adaptive bulbous bow, with variable geometry, able to improve the total hull ship resistance, in different loading and navigational conditions revealed drag reduction of up to ten per cent as well as savings of up to four per cent in terms of ship resistance. Towing tests on the scale demonstrator - Towing tank tests on five bow models and CFD analysis of an existing ship have shown significant saving potential under realistic operational conditions. Scale demonstator performed in University Dunarea de Jos of Galati. 10

11 3D view on the design of full scale adaptive bulb demonstrator for a small passenger ship; design by SDG and assessment by HSVA. Alexandru Varlan, Executive Manager, Navrom Shipyard Galati, Romania the involvement of Navrom Shipyard in the ADAM4EVE project represents an open window to new ideas and technologies. Stefan Giuglea, Deputy Managing Director, Ship Design Group, Romania According to the analysis within the ADAM4EVE project, a quick return on investment (ROI) can be expected thanks to low installation costs. ADAM4EVE

12 Adaptive and smart materials and structures for more efficient vessels Adaptive window increases comfort on yachts Sailing yachts are exposed to hours of sunlight during daytime resulting in increased temperatures inside the cabins. At the same time, undisturbed external view is desired as the sun sets. With novel adaptive windows installed to the exterior of the yacht, the transparency of the window can be adjusted according to the user s needs and desires. Adaptive technology is based on thin electrochromic layer in between the safety glazing. The transparency of the window can be activelly controlled through a switch. Sailing yacht Saare 38 12

13 Experimental tests have shown the efficiency and sufficient strength of the developed window concept. Peeter Sääsk, Board Member, AS Saare Paat, Estonia This project has been a great experience for AS Saare Paat. If we can make the solution more attractive and cheaper for the end-user, then I am certain that this solution will be widely used in the future. Kristjan Tabri, Board Member, MEC Insenerilahendused The development of an adaptive window for a sailing yacht was an excellent example how the technical solutions established for civil or aeronautical sectors are transferred to marine field. I belive that in notso-distant future we will see such solution used in the marine sector. ADAM4EVE

14 Adaptive and smart materials and structures for more efficient vessels Adaptive rudder-propeller improves manoeuvring, consumption and safety Ferry vessels and yachts manoeuvring criteria are based on the requirements for the frequent berthing at the terminals. Tunnel stern thrusters are ineffective so the only present solution is to install two controllable pitch propellers (CPPs) or pods. However, the present solution reduces the ship efficiency in seagoing conditions. Therefore, the effective adaptive manoeuvring propulsion is required. The ADAM4EVE idea is to develop the adaptive rudder-propeller i.e. spade rudder with incorporated electric motor to drive an auxiliary propeller. The newly developed rudder-propeller will have the possibility to operate at design pitch during manoeuvring in port or locked at 90 pitch in vertical plane as an extension of spade rudder at seagoing condition. Three different rudder propeller arrangements were developed. For two arrangements, a model scale demonstrator has been built and hydrodynamic propulsion model tests were conducted in the towing tank facilities at VTT and compared with the base design. 14

15 For the most promising arrangement, additional open water model tests were conducted in order to determine the rudder propeller performance as a thruster. Djani Dundara, Senior Designer, Uljanik Shipyard As several detailed issues still remain to be solved, the close cooperation with Classification Societies is necessary, but the overall feeling from several HAZID meetings is that, once these details are taken care of, they can be dealt with usual Class instruments. ADAM4EVE

16 Adaptive and smart materials and structures for more efficient vessels Discovering potentials further assessments, studies and perspectives Further to the prototypes introduced on the preceding pages, ADAM4EVE developed further smart ideas and made corresponding design studies, and various research was done to assess ADAM4EVE solutions in terms of technical properties, economic and ecologic impact, and potential hazards. Thermal and novel structural materials Researchers characterised insulation, storage capabilities and other thermal properties of various adaptive paints and structural materials, and they also investigated the producability of solutions featuring such materials. But would these materials be able to withstand the harsh conditions at sea? As a first attempt to answer this question, material experts and end users teamed up to undertake prototype tests. Novel structural materials Smaller, more efficient, control surfaces. Ships rudders are incredibly important for the directional stability and manoeuvrability of a ship. A small study investigated the ability to use an adaptive surface to increase the effectiveness of a rudder thus enabling it to be smaller and therefore efficient. Tests were conducted both on materials to produces aircraft wing type flaps and the assessment of the concept was demonstrated in a towing tank. Mike Collier, Manager Research & Project, Carnival Cruises: Fraunhofer IFAM did a field test of a new thermochromic paint system on one of our cruise ships. The paint could change its state from reflecting (white) at warm temperatures to absorbing (black) at cool temperatures. This pragmatic exercise greatly helped bridging the gap between basic research and testing on real operating conditions. The benefits of the technology have become very obvious. 16

17 Fire and safety Researchers developed a thin thermochromic coating capable of modifying its optical properties when heated and which can be applied to solid materials like glass or concrete. When the surface of the coated material is cold, the coating allows heat to be transmitted and absorbed by the material, but when its temperature rises to a certain limit, the coating experiences a change in its microstructure and reflects heat. This change increases not only the fire performance of windows and solid surfaces but the thermal insulation of the vessel, reducing the energy requirements of HVAC systems. SP also tested the performance of coated windows and normal windows. Results show that thermochromic windows importantly inhibit the propagation of fires and help enhancing the climate comfort in the vessels. ADAM4EVE

18 Adaptive and smart materials and structures for more efficient vessels Discovering potentials further assessments, studies and perspectives Economic/Ecologic In order to attain global (environmental) sustainable development, it is of paramount importance for the Maritime Industry to reduce the amount of emissions and the Global Warming Potential (GWP) in all their current and future operational strategies. The Life Cycle Analysis (LCA) results helped to formulate optimal operational strategies for integration of the ADAM4EVE technologies with reduced emissions and fuel consumption. The Life Cycle Costing (LCC) results helped to formulate profitable economic models (Net Present Value, Return on Investment) to introduce the Adaptive Smart Technologies in an environmental sustainable model. Life cycle performance assessment results for one of the ADAM4EVE prototypes, showing the development of the Net present value for two realistic operational scenarios. 18

19 Prof. Fai Cheng, Head of Strategic Research and Technology Policy, Lloyd s Register EMEA, United Kingdom The ADAM4EVE Project has demonstrated many new and innovative technologies allowing ships to react and adapt to changing environment. The implementation of these technologies on ships will enable them to become smarter and greener, bringing great benefits to environmental protection and operational safety. It should also encourage more investment to support research and development to bring these technologies to full implementation on ship design, construction and operation. Paolo Salza, Chief Technical Officer, RINA, Italy The opportunity to work directly with research institutes and shipyards for material definition and assessment provide valuable know-how for introducing innovative solutions in the shipbuilding industry and in the regulatory framework for classification societies. Prof. Pandeli Temarel, Head of Academic Unit, Civil, Maritime and Environmental Engineering and Science, University of Southampton, UK Ships that adapt to their operational conditions is an inspiring concept and provides a technological edge with which to attract more future maritime engineers. Dr. Sc. Alan Klanac, President of the Board, Jadrolinija d.d. Rijeka, Croatia Jadrolinija recognises the importance of the ADAM4EVE project which aims to improve the quality of the shipbuilding industry through the use of smart materials. The presented prototypes, both of composite and adaptive materials, are very applicable and will bring concrete benefits to the industry. ADAM4EVE

20 Adaptive and smart materials and structures for more efficient vessels Catalogue of Project results Catalogue of suitable design principles of actuated surfaces for creating geometric hull-form modification Structural design and production methodology for the creation of adaptive hull structures for use in flow field modification, and associated hydrodynamic performance indication Catalogue, assessment report and guidelines on new active and passive smart materials for outfitting of vessels indicating the different adaptive solutions usefulness for maritime applications Test data base Report on assessment methodologies and first results, completion of testing results (data) on mechanical, hydrodynamic, optical, fire and thermal properties Technical guidelines Reports on applicable rules and risks, safety assessment, fire properties assessment and testing; and related provisional guidelines Assessment of Life Cycle Performance and sustainability Establishment of a suitable methodology and relevant performance indicators, setup of LCPA models, and execution of assessments on all ADAM4EVE application cases Design studies for Cruise Ships (Adaptive damping of engine bed foundations, Fire protection window) aiming at improved passenger comfort and increased accommodation areas, and improved safety Design study and Prototype Application for Cruise Ships (Adaptive damping of bow thrusters) aiming at improved passenger comfort and increased accommodation areas Design study and Prototype Application for RoPax vessels (Adaptive Aft of Ro- Pax) aiming at optimum resistance at varying speed and draught Design study for RoPax vessels (Adaptive bulbous bow) aiming at improved hydrodynamic properties when operating under off-design conditions 20

21 Design study for ferries and yachts (Adaptive rudder propeller) aiming at fuel consumption reduction, increased manoeuvring capability in seagoing condition and ports, emergency take me home functionality, increased manoeuvring capability in ports, weight reduction, increased cargo capacity (ferry) and accommodation area (yacht) Design study for small yachts (Adaptive rudder) aiming at increased manoeuvrability and fuel oil consumption reduction during sailing Design study for lifestock carriers (Climate control of the uppermost deck and side walls cargo deck panel) aiming at heat take-up reduction, heat regulation on the upper deck and shell plating, light ship weight reduction and maintenance cost reduction Design study and Prototype Application for Reefer/Train ferry ship (Adaptive thermal insulation panels) aiming at weight reduction, reduction of energy demand for air conditioning thanks to improved insulation and storage of latent heat Design study for IWW ships (Adaptive system for deck house vibration damping) aiming at improved comfort and better working conditions for crew Design study and Prototype Application for IWW passenger vessel (Adaptive bulbous bow) aiming at reducing the total ship hull resistance Design study and Prototype Application for Yacht (Adaptive windows with variable shading capabilities) aiming for increased wellbeing and reduced energy demand for air conditioning Design study and Prototype Application for Ship model (Building and utilisation of adaptive and modular models) CFD tests, building of adaptive and modular models, and performance of model tests related to the abovementioned studies Adaptive Aft of RoPax and adaptive rudder, comparing several rudder designs (or stern flap geometries) to conventional designs; 3D printing of propeller blades was successfully demonstrated ADAM4EVE

22 Adaptive and smart materials and structures for more efficient vessels ADAM4EVE The Outcomes and Beyond A living creative project. About three years ago, ADAM4EVE embarked with the innovative idea to make ship materials and structures able to adapt flexibly to changing conditions. The project always had a practical approach, aiming to develop solutions which would be applicable in typical products of the European industry represented by the five application cases in short or medium term after the end of the project. We went through a creative process: some initial ideas had to be modified to achieve a more robust and realistic application perspective. Others, considered very ambitious at first, turned out to be achievable thanks to previous developments or other industries solutions. I would like to thank all partners who actively and openly contributed to this lively project, the European Commission services which always showed a helpful attitude towards the project and especially the coordinator, Matthias Krause, who smoothly and reliably ran the process. outgoing and cooperative However, the success of ADAM4EVE is also a result of efficient communication and cooperation with the world around us. The attendees of the project s technical workshops gave valuable feedback, and many collaborating companies provided various materials for testing. Other project consortia and associations supported us by means of fruitful discussions and helping us in disseminating our findings. In particular I would like to mention the E-LASS network ( which provided an efficient platform for communication with the lightweight community, the MESA project and the Vessels for the Future research association ( which took up the R&D needs we defined in their agendas, and the European Factories of the Future Association ( which provides a discussion platform with the manufacturing industry. I would like to express my gratitude to all these organisations and persons. The project consortium and CMT as an association will continue this fruitful cooperation after the end of the project. 22

23 leading to tangible results and clear exploitation potentials More than 20 results have been identified, which are useable by specific consortium partners or beyond. Some results such as innovative glass, coatings and insulation materials are mature enough for using them in commercial products in the near future, yielding significant energy savings especially for air conditioning. Others like adaptive hull structures have proven feasibility, but more research, development and testing is required. This has been included in the maritime strategic research agendas. A variety of results can be adapted to other, similar application cases, contribute to the data and knowledge repository of the European industry or will be used for new educational programmes for young engineers and specialists. Assuming a range of realistic operational scenarios and comparing the ADAM4EVE results with conventional designs, the project results have been carefully analysed in view of their potential impact on life cycle costs and environment. As an example, for a straightforward design like an adaptive stern flap the ROI period is measured in months, not years. In addition, using phase change material for insulation on reefer vessels, the energy savings can sum up to more than 5%. Joint IPR workshops with the support of GuardShip and the development of strat- egies how to protect intellectual property have found their way into the exploitation plans of the partners, but also increased the consortium partners general awareness on this important aspect of applied research. Looking back at ADAM4EVE and the results we have achieved, we can proudly say that altogether we have met our goals and made the project a true success. I hope, the reader also found our brochure interesting, gained new ideas and found valuable information for his business or research. The coordinator as well as all partners of ADAM4EVE are at your disposal to provide additional information and discuss any option of future cooperation. We are looking forward to hearing from you! Dr. Frank Roland Managing Director of Center of Maritime Technologies e. V. ADAM4EVE

24 Contact: Matthias Krause CENTER OF MARITIME TECHNOLOGIES e. V. Bramfelder Str. 164 D Hamburg Germany Tel.: +49 (40) Partners Center of Maritime Technologies, Germany Uljanik Brodogradiliste, Croatia Rina Services Spa Rina, Italy Flensburger Schiffbau-Gesellschaft Mbh & Co, Germany Fraunhofer-Gesellschaft zur Foerderung der angewandten Forschung, Germany VTT Technical Research Centre of Finland Ltd, Finland Lloyd s Register Emea, United Kingdom SP Sveriges Tekniska Forskningsinstitut, Sweden as2con-alveus, Croatia University of Southampton, United Kingdom Ship Design Group Srl, Romania Universitatea Dunarea de Jos din Galati, Romania STX France, France Compania Trasmediterranea, Spain Acciona Infraestructuras, Spain Hamburgische Schiffbau-Versuchsanstalt Gmbh, Germany Carnival Plc, United Kingdom SC Navrom Shipyard, Romania MEC Insenerilahendused, Estonia Saare Paat, Estonia Hutchinson Paulstra, France 2015 The ADAM4EVE Consortium This document may not be copied, reproduced or modified in whole or in art for any purpose without written permission from the ADAM4EVE Consortium. This brochure reflects the views only of the author(s), and the European Union cannot be held responsible for any use which may be made of the information contained therein.