YEAR 2021
DEVELOPMENT OF A MULTIFUNCTIONAL MODULAR VESSEL CONCEPT BASED ON LIGHTWEIGHT STRUCTURES AND FLEXIBLE MANUFACTURING PROCESSES
(IN852A 2018/79)
The main objective of the MODULIGHT project has been the development of modular, multi-purpose and lightweight barges, through the introduction of multi-material structures based on the combination of steel and composite, in order to obtain versatile and customizable vessels that allow modules to be exchanged easily, thus making it possible to transport different quantities and types of cargo without the need for a fleet of barges of different types, or to go to the shipyard to refit each barge to adapt it to the new type of cargo to be transported.
The need for initiatives such as MODULIGHT stems from the naval sector’s interest in overcoming some of the particularities that limit its growth and profitability, both globally and in Galicia in particular, such as its project-based production models, which are clearly different from the mass or series production of other sectors. Thus, ships are currently designed and built as one-off projects, which results in considerable production inefficiency, not only in tedious phases such as the approval of new designs by Classification Societies, but in countless stages such as the preparation of the design itself, the programming of manufacturing sequences, the design of tooling or the qualification of welding procedures. All of them end up generating considerable cost overruns, which limit the profitability of the stakeholders involved.
On this basis, MODULIGHT has pursued a paradigm shift in ship manufacturing and design, so as to maximize the efficiency of short production runs and make the shipbuilding process as a whole more flexible. To this end, it has pursued a production model based on the combination of the concepts of modularization and standardization, relying on the development of advanced joining technologies and manufacturing processes as key enabling technologies. In addition, the introduction of multi-material (steel-composite) structures in strategic areas of the vessel to lighten the structure has been proposed, with clear environmental, structural and logistical implications. Ultimately, this will make it possible to save on manufacturing costs and on the costs incurred by shipowners, while also reducing energy consumption.
In the fourth and final year of the project, 2021:
– The manufacturing process of the demonstrators (barge modules) has been completed.
– The calculations needed to define the validation strategy, based on the application of loads to the demonstrators, have been carried out.
– The virtual analysis and physical testing of the demonstrators have been carried out at CARDAMA’s facilities.
– The final design of the modular vessel has been completed and the latest updates to the detailed engineering have been made, based on the information obtained in the validation phase.
– Based on the manufacturing and validation activities of the demonstrators, guidelines have been agreed with the aim of facilitating the design and manufacture of multifunctional modular vessels through the incorporation of new multi-material solutions and joining technologies.
MODULIGHT CONSORTIUM
The MODULIGHT consortium covers the entire value chain involved in the development of multifunctional and lightweight modular vessels, with companies of proven experience and know-how in each of the technical aspects addressed:
ASTILLEROS FRANCISCOCARDAMA, which, as shipyard and consortium leader, defined the case study based on the development of a multi-purpose river vessel.
INSENAVAL, an engineering firm that has been responsible for developing the calculation and design of the vessel, from conceptual design to detailed engineering.
GALVENTUS SERVICIOS EÓLICOS, which has developed enabling technologies for modular manufacturing, including steel-composite multi-material manufacturing concepts.
INDUSTRIASFERRI, which has been responsible for developing non-conventional joining technologies, ranging from intra- and inter-modular joints to joints with deck components.
The consortium has had the participation of the AIMEN Technology Centre, an entity with a considerable track record in the development of multi-materials and joining technologies, and with extensive knowledge of the naval sector.
PROJECT FUNDING
This MODULIGHT project, part of the CONECTAPEME 2018 programme, is funded by the Xunta de Galicia through the Axencia Galega de Innovación (GAIN, Galician Innovation Agency) with the support of the Consellería de Economía, Emprego e Industria (Regional Ministry of Economy, Employment and Industry), and is co-funded by FEDER Funds under axis 1 of the Feder Galicia 2014-2020 operational programme.
YEAR 2020
DEVELOPMENT OF A MULTIFUNCTIONAL MODULAR VESSEL CONCEPT BASED ON LIGHTWEIGHT STRUCTURES AND FLEXIBLE MANUFACTURING PROCESSES
(IN852A 2018/79)
The main objective of the MODULIGHT project is the development of modular, multi-purpose and lightweight barges, through the introduction of multi-material structures based on the combination of steel and composite, in order to obtain versatile and customizable vessels that allow modules to be exchanged easily, thus making it possible to transport different quantities and types of cargo without the need for a fleet of barges of different types, or to go to the shipyard to refit each barge to adapt it to the new type of cargo to be transported.
The need for initiatives such as MODULIGHT stems from the naval sector’s interest in overcoming some of the particularities that limit its growth and profitability, both globally and in Galicia in particular, such as its project-based production models, which are clearly different from the mass or series production of other sectors. Thus, ships are currently designed and built as one-off projects, which results in considerable production inefficiency, not only in tedious phases such as the approval of new designs by Classification Societies, but in countless stages such as the preparation of the design itself, the programming of manufacturing sequences, the design of tooling or the qualification of welding procedures. All of them end up generating considerable cost overruns, which limit the profitability of the stakeholders involved.
On this basis, MODULIGHT pursues a paradigm shift in ship manufacturing and design that makes it possible to maximize the efficiency of short production runs and make the shipbuilding process as a whole more flexible. To this end, it pursues a production model based on the combination of the concepts of modularization and standardization, relying on the development of advanced joining technologies and manufacturing processes as key enabling technologies. In addition, it proposes the introduction of multi-material (steel-composite) structures in strategic areas of the vessel to lighten the structure, with clear environmental, structural and logistical implications. Ultimately, this will make it possible to save on manufacturing costs and on the costs incurred by shipowners, while also reducing energy consumption.
In the third year of the project, 2020:
– The refinement and optimization activities for the design of the modular vessel have been completed.
– Within the multi-material manufacturing strategies, and as a continuation of the activities carried out in 2019, work this year has focused on scaling up the solutions, as an intermediate step in preparing the consortium prior to the manufacture of the demonstrators.
– The various inter-modular and intra-modular joints have been manufactured and have undergone validation prior to their assembly on the demonstrators.
– The demonstrators (barge modules) have been designed and considerable progress has been made in their manufacturing process.
– Finally, in parallel with the manufacture of the demonstrators, considerable progress has been made on the final design of the modular vessel and on the detailed engineering activities.
MODULIGHT CONSORTIUM
The MODULIGHT consortium covers the entire value chain involved in the development of multifunctional and lightweight modular vessels, with companies of proven experience and know-how in each of the technical aspects addressed:
ASTILLEROS FRANCISCOCARDAMA, which, as shipyard and consortium leader, defined the case study based on the development of a multi-purpose river vessel.
INSENAVAL, an engineering firm that is responsible for developing the calculation and design of the vessel, from conceptual design to detailed engineering.
GALVENTUS SERVICIOS EÓLICOS, which is developing enabling technologies for modular manufacturing, including steel-composite multi-material manufacturing concepts.
INDUSTRIASFERRI, which is responsible for developing non-conventional joining technologies, ranging from intra- and inter-modular joints to joints with deck components.
The consortium has the participation of the AIMEN Technology Centre, an entity with a considerable track record in the development of multi-materials and joining technologies, and with extensive knowledge of the naval sector.
PROJECT FUNDING
This MODULIGHT project, part of the CONECTAPEME 2018 programme, is funded by the Xunta de Galicia through the Axencia Galega de Innovación (GAIN) with the support of the Consellería de Economía, Emprego e Industria, and is co-funded by FEDER Funds under axis 1 of the Feder Galicia 2014-2020 operational programme.
YEAR 2019
DEVELOPMENT OF A MULTIFUNCTIONAL MODULAR VESSEL CONCEPT BASED ON LIGHTWEIGHT STRUCTURES AND FLEXIBLE MANUFACTURING PROCESSES
(IN852A 2018/79)
The main objective of the MODULIGHT project is the development of modular, multi-purpose and lightweight barges, through the introduction of multi-material structures based on the combination of steel and composite, in order to obtain versatile and customizable vessels that allow modules to be exchanged easily, thus making it possible to transport different quantities and types of cargo without the need for a fleet of barges of different types, or to go to the shipyard to refit each barge to adapt it to the new type of cargo to be transported.
The need for initiatives such as MODULIGHT stems from the naval sector’s interest in overcoming some of the particularities that limit its growth and profitability, both globally and in Galicia in particular, such as its project-based production models, which are clearly different from the mass or series production of other sectors. Thus, ships are currently designed and built as one-off projects, which results in considerable production inefficiency, not only in tedious phases such as the approval of new designs by Classification Societies, but in countless stages such as the preparation of the design itself, the programming of manufacturing sequences, the design of tooling or the qualification of welding procedures. All of them end up generating considerable cost overruns, which limit the profitability of the stakeholders involved.
On this basis, MODULIGHT pursues a paradigm shift in ship manufacturing and design that makes it possible to maximize the efficiency of short production runs and make the shipbuilding process as a whole more flexible. To this end, it pursues a production model based on the combination of the concepts of modularization and standardization, relying on the development of advanced joining technologies and manufacturing processes as key enabling technologies. In addition, it proposes the introduction of multi-material (steel-composite) structures in strategic areas of the vessel to lighten the structure, with clear environmental, structural and logistical implications. Ultimately, this will make it possible to save on manufacturing costs and on the costs incurred by shipowners, while also reducing energy consumption.
In summary, the objectives set will be achieved through the development of the following technological and sectoral milestones:
- Development of new production strategies in shipbuilding, in order to build vessels that are highly efficient in use at an optimized cost.
- Advancing new ship concepts, including the concepts of modularity and multifunctionality.
- Advancing maritime innovation in order to design and build high-value-added vessels with optimized life-cycle costs and a lower environmental impact.
- Implementing demonstrator manufacturing and testing tasks that make it possible to validate different aspects of the design, scale up the solutions developed and facilitate analysis by Classification Societies or potential shipowners.
- Contributing to the innovation culture of the Galician shipbuilding industry and its supply chain.
- Contributing to the improvement of global competitiveness and preparing for the expected market evolution in river transport.
MODULIGHT CONSORTIUM
The MODULIGHT consortium covers the entire value chain involved in the development of multifunctional and lightweight modular vessels, with companies of proven experience and know-how in each of the technical aspects addressed:
CARDAMA SHIPYARD, which, as shipyard and consortium leader, has defined the case study based on the development of a multi-purpose river vessel.
INSENAVAL, an engineering firm that is responsible for developing the calculation and design of the vessel, from conceptual design to detailed engineering.
GALVENTUS SERVICIOS EÓLICOS, which is developing enabling technologies for modular manufacturing, including steel-composite multi-material manufacturing concepts.
INDUSTRIASFERRI, which is responsible for developing non-conventional joining technologies, ranging from intra- and inter-modular joints to joints with deck components.
The consortium has the participation of the technology centre** AIMEN**, an entity with a considerable track record in the development of multi-materials and joining technologies, and with extensive knowledge of the naval sector.
In this second year, 2019, considerable emphasis has been placed on the activities related to the design of the modular vessel and its refinement, thus achieving a high degree of definition. In addition, different manufacturing strategies have been explored and developed. This involves both adjusting the process window and characterizing the properties of these multi-material structures. Finally, it is worth highlighting the work carried out on the definition and design of the various inter-modular and intra-modular joints. This has involved both physical testing and calculations using FEM tools.
**PROJECT FUNDING **This MODULIGHT project, part of the CONECTAPEME 2018 programme, is funded by the Xunta de Galicia through the Axencia Galega de Innovación (GAIN) with the support of the Consellería de Economía, Emprego e Industria, and is co-funded by FEDER Funds under axis 1 of the Feder Galicia 2014-2020 operational programme.
YEAR 2018
DEVELOPMENT OF A MULTIFUNCTIONAL MODULAR VESSEL CONCEPT BASED ON LIGHTWEIGHT STRUCTURES AND FLEXIBLE MANUFACTURING PROCESSES
(IN852A 2018/79)
The main objective of the MODULIGHT project is the development of modular, multi-purpose and lightweight barges, through the introduction of multi-material structures based on the combination of steel and composite, in order to obtain versatile and customizable vessels that allow modules to be exchanged easily, thus making it possible to transport different quantities and types of cargo without the need for a fleet of barges of different types, or to go to the shipyard to refit each barge to adapt it to the new type of cargo to be transported.
The need for initiatives such as MODULIGHT stems from the naval sector’s interest in overcoming some of the particularities that limit its growth and profitability, both globally and in Galicia in particular, such as its project-based production models, which are clearly different from the mass or series production of other sectors. Thus, ships are currently designed and built as one-off projects, which results in considerable production inefficiency, not only in tedious phases such as the approval of new designs by Classification Societies, but in countless stages such as the preparation of the design itself, the programming of manufacturing sequences, the design of tooling or the qualification of welding procedures. All of them end up generating considerable cost overruns, which limit the profitability of the stakeholders involved.
On this basis, MODULIGHT pursues a paradigm shift in ship manufacturing and design that makes it possible to maximize the efficiency of short production runs and make the shipbuilding process as a whole more flexible. To this end, it pursues a production model based on the combination of the concepts of modularization and standardization, relying on the development of advanced joining technologies and manufacturing processes as key enabling technologies. In addition, it proposes the introduction of multi-material (steel-composite) structures in strategic areas of the vessel to lighten the structure, with clear environmental, structural and logistical implications. Ultimately, this will make it possible to save on manufacturing costs and on the costs incurred by shipowners, while also reducing energy consumption.
In summary, the objectives set will be achieved through the development of the following technological and sectoral milestones:
- Development of new production strategies in shipbuilding, in order to build vessels that are highly efficient in use at an optimized cost.
- Advancing new ship concepts, including the concepts of modularity and multifunctionality.
- Advancing maritime innovation in order to design and build high-value-added vessels with optimized life-cycle costs and a lower environmental impact.
- Implementing demonstrator manufacturing and testing tasks that make it possible to validate different aspects of the design, scale up the solutions developed and facilitate analysis by Classification Societies or potential shipowners.
- Contributing to the innovation culture of the Galician shipbuilding industry and its supply chain.
- Contributing to the improvement of global competitiveness and preparing for the expected market evolution in river transport.
MODULIGHT CONSORTIUM
The MODULIGHT consortium covers the entire value chain involved in the development of multifunctional and lightweight modular vessels, with companies of proven experience and know-how in each of the technical aspects addressed:
ASTILLEROS FRANCISCOCARDAMA, which, as shipyard and consortium leader, will define the case study based on the development of a multi-purpose river vessel.
INSENAVAL, an engineering firm that will develop the calculation and design of the vessel, from conceptual design to detailed engineering.
GALVENTUS SERVICIOS EÓLICOS, will develop enabling technologies for modular manufacturing, including steel-composite multi-material manufacturing concepts.
INDUSTRIASFERRI, which will be responsible for developing non-conventional joining technologies, ranging from intra- and inter-modular joints to joints with deck components.
The consortium will have the participation of the technology centre** AIMEN**, an entity with a considerable track record in the development of multi-materials and joining technologies, and with extensive knowledge of the naval sector.
**PROJECT FUNDING **
This MODULIGHT project, part of the CONECTAPEME 2018 programme, is funded by the Xunta de Galicia through the Axencia Galega de Innovación (GAIN) with the support of the Consellería de Economía, Emprego e Industria, and is co-funded by FEDER Funds under axis 1 of the Feder Galicia 2014-2020 operational programme.