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Copyright © 1999 Adams Business Media, Inc. Would You Like A Reprint of
this Article? Beneath the Surface Four Case Studies of Innovative Marine Technology by Frances Richards Marine applications literally bring a whole new world of challenges to design engineers. Unique environmental conditions, pressures, temperatures, power sources, materials suited to water and more are the types of considerations OEM designers must confront. The innovations are as varied as the applications they serve. The following four case studies illustrate not only the breadth of marine applications in use, but the problem/solution orientation of the companies and technologies highlighted. Automatic AC Electrical System Solves Problem for Tiara Yacht Designers When Leon Slikkers of S2 Yachts made the decision to build the new Tiara 50' Express, his goal was to make dramatic improvements in boats of this class and size. In discussions with Dan Springer, S2's director of engineering, one particular area of interest was the AC electrical system. The overall challenge was to automatically manage AC power on board in the safest and most user-friendly way possible. The engineering staff drew from its own design and boating experiences, as well as input from customer service representatives and feedback from Tiara owners and focus groups. The questions and wish list grew quickly. How do we isolate the boat from adjacent or shoreside problems? What if there is low voltage? We have 220 volt panels, but what if only 30 amp 110 volt is available? How do we get power from A and B bus if only one input is available? How do we switch back and forth from shorepower to genset? The list went on and on.
A further requirement was that everything had to be consistent with ABYC standards and consist of Marine UL listed equipment where available. That took care of the questions and the wish list with the exception of who would be able to partner with S2 on this project. Dan Springer approached Charles Marine Products, Rolling Meadows, IL. After reviewing S2's functional requirements for an automated system, it was determined that some existing Charles products would successfully meet the requirements and some new products would need to be developed to complete the wish list. One existing product used in the Tiara case was the Charles Iso-Boost product, a combination marine isolation and boosting transformer. The transformer is fully encapsulated and has a full current carrying shield per ABYC. The ground (green) wire from the dock deadends in the shield of the transformer and, as such, there is no physical wire connection between the yacht and the dock. The automatic boosting feature allows for a fifteen percent boost when the PC board senses voltage below 210 volts from the dock. The Iso-Boost also has an added feature of shutting down the air conditioning system if the dock current drops dangerously low, which helps protect valuable equipment. This product meets the requirement of electrically isolating the yacht from the dock as well as boosting low dock voltage. The Charles 3.8 KVA international marine isolation transformer has the capability
through wiring specific "taps" to step up 110 volt AC input to 200 volt AC
output. It also performs the same isolation function as the Iso-Boost. Thus, if only a
single 110 volt 30 amp service was available, fully isolated 220 volt 15 amp power would
be available to New Product Required: Automatic Switch Box Next came the challenge to automatically select the first input and lock out the second source. No off-the-shelf product was available for this, though the concept is fairly simple -- build a box with interlocking contactors that sense first in-current. With machinery space aesthetics in mind, the same enclosure as the 3.8 KVA transformer was used. The Iso-Boost product uses interlocking contactors to switch back and forth between the direct and the boost mode. Charles engineers used existing hardware and technology to develop the automatic switch box and the Charles Automatic A/B selector (ABSEL) was born. Tiara's application necessitated two separate products, one for 110 volt and one for 220 volt. Final Challenge: Developing the Smart Box The final and most challenging requirement was to develop a smart box that would accept four AC inputs (two shorepower and two gensets) and have it direct whatever power available to the electrical distribution panel. This was the genesis of what was to become the Charles AC automatic master control(ACMC). The decision was made to use the same enclosure as the Iso-Boost to add some visual balance to the group of boxes that would comprise the Tiara 50's automatic AC input system. Existing hardware could be used, but a new PC board would need to be developed to think for the system. Charles lead marine engineer, Jake Kaiser, drew from his experiences developing the Iso-Boost PC board while he developed the ACMC. Ongoing communication between S2's engineering group and Charles engineers finalized the features of the ACMC. The ACMC would have two A inputs (one shore, one genset) to feed the A bus and two B inputs (again, one shore, one genset) to feed the B bus. If only one input is detected, the missing input feature would automatically parallel both A and B buses. Shore power is the dominant (master) input. To avoid "hot swaps," five seconds after shore power is energized and if the same input genset is running, the ACMC will take the genset off line and after a three second delay, engage shore power. The yacht's AC system can then access power from a myriad of single or combination A and/or B inputs. All the captain needs to do is assess what power is available to the yacht and energize accordingly. All of the output is done automatically and with no manual switchgear. S2, in partnership with Charles Marine Products, has answered the challenge of bringing AC power on board in a safe and convenient manner. Replacing Steel Wire Rope with High-Strength Whitehill Docking Lines Increases Workplace Safety and Offers Savings For decades, steel wire ropes have been the maritime industry's choice material for tow hawsers, as well as for tug and tanker mooring lines. Despite the fact that they are heavy, bulky and require numerous personnel for handling, steel-wire ropes provided mariners with a high-tenacity, low-cost and durable rope product. These advantages were enough to offset "natural" difficulties from corrosion, deterioration under heavy usage, fraying and handling difficulties. Also, environmental regulations -- mainly the Clean Water Act -- have added a new concern. Traditionally, it was necessary to lubricate the steel-wire lines if they were to have a life span of three to five years. However, since lubrication deposits an oil sheen on the water, it was ruled out by environmental legislation. With no lubrication permitted, the life cycle of steel-wire rope plummets to just one or two years.
ARCO Marine Inc., Long Beach, CA, adopted Spectra-made lines from Whitehill Manufacturing Corp., Chester, PA, more than two years ago as a replacement for steel-wire docking lines on its entire fleet. Recent studies by ARCO demonstrate two new benefits that make the fibers even more attractive for maritime use -- a reduction in injuries to deckhands and a significant time savings on the job. Regarding the latter, consider this: ARCO reports that replacing its fleet's steel-wire lines with new Spectra Fiber lines will cut annual docking time by 1,080 hours (or a month-and-a-half of full 24-hour-days) per year. On average, tankers carrying clean oil dock every two to three days(or 120 times-a-year). Using steel-wire ropes, docking takes from 60 to 75 minutes. With the new fiber lines, ARCO says the docking takes just 30 to 45 minutes, saving an hour each time the tanker docks and undocks. One ship saves five full 24-hour-days-per-tanker-per-year. For the nine tankers in the fleet that dock at this frequency the time saving is substantial. Of course, the savings in time results in a substantial cost savings in fuel, static time and manpower. Polyurethane System Adds Muscle to Extra Wide Water Skis
The company made its EP (Exceptional Performance) Wide Track water skis wider than other water skis so they are easier to ride. To add muscle to the skis, Wellington selected the black-pigmented Baydur 660 IBS polyurethane structural foam from Bayer's Polymers Division, Pittsburgh, PA, to give the ski a low-density, high-strength performance composite core. The Baydur foam's reaction injection molding RIM system incorporates a specially engineered interactive blowing system (IBS). The material's properties include large-part moldability, low-viscosity liquid molding, stiffness and excellent surface quality. "We have been using the Baydur 660 IBS material in Wellington's skis since it was first offered by Bayer," said John Lucius, vice president of development for Wellington Leisure Products. "In the EP Wide Track skis, the material flows well around the structure in the skis and fills the mold cavity well with no air bubbles." Lucius added that the Baydur 660 IBS polyurethane RIM system enabled Wellington, which performs its own molding and assembly, to reduce the labor that would be required if the ski were produced by compression molding. The 10 lb., 63-in. long EP skis are formed in a unique parabolic shape that is wide at the front, narrows at the center near the binding and widens again at the back. Nearly 7/8 inches at its thickest point, the ski's top surface is flat in the center, but tapers up at the sides and forms a round-molded edge. The skis are offered in two styles -- as a pair for traditional skiing and as a very wide, single ski with two bindings for slalom skiing. Manufacturing of the ski starts with placing a proprietary, patented superstructure
into the mold tool. Using liquid composite molding, Wellington then injects the Baydur
foam into the mold. The polyurethane flows in and around the superstructure to form a
strong, sandwich construction. Four-color graphics are incorporated into the ski's top
surface through a proprietary process during The parabolic shape of the EP Wide Body skis helps them quickly climb out of the water and makes the skis more stable at slower speeds. Lucius said the skier can ride longer, farther and with less strain than with traditional skis. Next Generation Shipbuilding with CATIA Computer-Aided Design
Shipbuilders such as the 100-year-old submarine manufacturer Electric Boat, Groton, CT, realize that a highly efficient business model -- one that reduces the huge costs and hours normally associated with shipbuilding -- is critical to success in a period where time and money are everything. Following the computer-aided-design (CAD) trend, Electric Boat turned to IBM and Dassault Systems for their shipbuilding design needs. Building a Virtual Boat Electric Boat's solution goes far beyond simple CAD, which still relies on traditional prototyping. With CATIA, Electric Boat's design/build teams and its customers can work concurrently to determine the best place to install pumps, pipes, air-conditioning ducts and other equipment by viewing and manipulating three-dimensional digital mock-ups. Being able to view the entire design in 3D makes communicating ideas much easier and more effective. Answers to technical considerations are arrived at by taking the design as far as possible before actual construction begins. For example, Electric Boat created the NSSN for the US Navy -- from concept through manufacturing simulation -- on computers, even before the steel for the first boat was ordered. This allowed for any potential design or manufacturing problems to be detected and corrected ahead of time and at minimal cost. Traditional prototyping requires a large number of wooden mockups to be built for testing designs. Using CATIA has allowed Electric Boat to reduce the number of these mockups by 75 percent. For more information, contact: Charles Industries, Ltd., Charles Center, 5600 Apollo Dr, Rolling Meadows, IL 60008. 847-806-6300. http://www.charlesin dustries.com Circle 706. S2 Yachts, 725 East 40th St, Holland, MI 49423. 616-392-7163. Circle 707. Allied Signal Performance Fibers, PO Box 31, Petersburg, VA 23804. 800-695-5969. http://www.alliedsignal.com Circle 701. Arco Marine Inc., 300 Ocean Gate Blvd, Long Beach, CA 90802. 562-590-4400. http://www.arco.com Circle 702. Whitehill Manufacturing Corporation, 2540 Green St, Chester, PA 19013. 610-494-2378. http://www.whitehillmfg.com Circle 703. Bayer Corporation, Polymers Division, Marketing Communications Group, 100 Bayer Rd, Pittsburgh, PA 15205-9741. 800-622-6004. http://www.bayer.com/polymers-usa Circle 705. Wellington Leisure Products, 1140 Monticello Rd, Madison, GA 30650. 706-342-1916. http://www.wellingtoninc.com Circle 704. Electric Boat (General Dynamics), 75 Eastern Point Rd, Groton, CT 06340-4989. 860-433-3000. http://www.gdeb.com Circle 708. IBM CATIA, 1507 LBJ Freeway, Dallas, TX 75234. 800-395-3339. http://www.catia.ibm.com Circle 709. Copyright © 1999 Adams Business Media, Inc. Would You Like A Reprint of
this Article? |
Dan Springer, along with Dennis Dodge, S2's electrical engineer,
pinpointed Tiara's requirements to maximize AC input capability and flexibility. There
would be an automatic selection of the first shoreside source from multiple fore or aft AC
inlets with an automatic lockout of the second source. The yacht was to be electrically
isolated from the dock and there was a provision to boost 208 dock voltage to 240 volts.
The 220 volts would be supplied to the panel from two possible 110 volt AC sources. The
system must sense multiple AC input sources and direct available power to the panel. All
of the above would be done automatically without manual switchgear.
For more than a dozen years Spectra Fibers have been making inroads on
a wide number of cordage applications. Spectra's high-strength polyethylene fiber,
developed by Allied Signal Inc., Petersburg, VA, is 10 times stronger than steel of equal
weight but lighter, naturally buoyant and resistant to wear-and-tear and degradation from
water, ultra-violet radiation and most chemicals. Its earliest uses were in advanced
technology for high-stress applications from ballistic armor for police to a wide variety
of ropes and cordage -- everything from kite string and parachute cords to marine hawsers
and lines.
A high-strength core material combined with an inventive, patented
design is the formula behind the success of a new line of water skis from Wellington
Leisure Products, Madison, GA.
Shipbuilding is one of the most challenging undertakings around.
Building anything from a submarine to a cruiseliner can cost in excess of $300 million
dollars and take between three and five years to complete. Some of these vessels are
considered the largest and most powerful modes of transportation in the world.