MarinePropulsionSystems

Edition 1.2014

4 News from the Regions

6 Cover Story

GalacticaStar: technicaleleganceindesign

9 Facts and Figures

10 News from ZF Marine Group

NewlocationforZFMarine inShanghai

10 News from the Global ZF Group

ZFbecomestechnicalsponsor ofTUDORUnitedSportsCar championship

11 Parts and Service

Faster,higher,stronger!

Impressreport Marine Propulsion SystemsAcustomermagazineforbusinesspartnersoftheZFMarineGroup

Published byZFFriedrichshafenAG–BusinessUnitMarinePropulsionSystemsEhlersstr.5088046Friedrichshafen,GERMANYPhone +49(0)7541777375Fax +49(0)7541907375www.zf.com/marine

Editor in ChiefSabrinaMünchMarketing&Communication

Editorial ResponsibilityMartinMeissnerMarketing&Communication

Coverphoto:courtesyofHeesenYachts

A new concept of hull design makes yachts more efficient on average

than any equivalent hull at speeds in excess of 15 knots up to 44 knots.

Page6

Matthias BenzExecutiveVP,IndustrialTechnologyBusinessUnitMarinePropulsionSystems

The physical action of putting up the new wall calendar in my office is something I secretly enjoy each Janu­ary. I realize all the exciting opportunities and challen­ges that are yet to be experienced in the coming year. There’s definitely an excitement in the anticipation of what’s to come. What’s to come – that’s an exciting state ment in and of itself, and one that I think embo­dies ZF Marine in 2014. 2013 was a pivotal year for the ZF Marine team. The results of which can be seen in our significantly improved financial performance as we closed the books last year.

Sales momentum continues to build for the ZF Marine group, and we see a very strong start to the year for our Commercial and Fast Craft product line. We will be introducing new products to our commercial craft family supporting our strategy for continuous growth in this segment. I’m very proud of the team at our facilty in Krimpen, Netherlands, who completed a success­ful turnaround of their business activities, and show continued exponential growth for the coming years. The global pleasure craft business continues to show slow but steady recovery, and gives us signs of hope. We’re committed to our continued investment in pro­ducts and technology to support our global plea sure boat customers.The global ZF Group’s “ZF 2025” strategic plan shows us the path for the organization over the next ten years.

My ThouGhTS,

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Our board of management sees the strength of the in­dustrial technology division, of which ZF Marine group is a key element. The board is committed to the marine sector; it’s attractive and strategic ally important for ZF.

We continue our efforts to keep you, our customers, at the center of our focus. 2014 is officially the “Year of Service” for ZF Marine. Our major focus this year is to take our already exemplary service support activities to the next level. It’s our goal to be the leader in marine propulsion aftermarket support. The ZF Marine team has hit the ground running this year. Their continued focus, hard work, dedication, and most of all enthu­siasm, will continue to keep us a top player in the ma­rine propulsion business. On behalf of the global ZF Marine team I thank you for your continued business. It’s my sincere hope that you are as excited as I am about what’s to come.

Thanks for your time.

report Marine Propulsion Systems 1.2014 54

West Coast Sales and Service –ZFMarinePropulsionSystemsMiramar,LLC

recentlyheldare-openingreceptionfortheirSalesandServicelocationinMukilteo,

Washington.ZFMarinerelocatedR&Dactivitiesandproductionfortheircontrols

familytotheirfacilityinArco,Italy.ThefacilityinMukilteowasrevampedtobetter

accommodateZFMarine’ssalesandsupportfunctionsintheregion.Inhisaddress

tostaffandcustomersattendingtheevent,WolfgangSchmid,ManagingDirector,

ZFMarinePropulsionSystemsMiramar,LLCreinforcedZFMarine’scommitmentto

theregion.Notonlyintheinvestmentinthefacilitybutinthemid-termplanstoadd

additionalworkshopspacetocreateasupportcenterforZF’scommercialthruster

productfamilyonthewestcoastoftheUSandCanada.

Eurocarrier Anna-B – DutchbuilderNeptuneShipyards

hasdeliveredtheEurocarrierAnnaBtoStematMarine

Services.Eurocarriersareamulti-purposeworkboatfor

harborconstruction,offshoreapplications,anchorhand-

ling,supply,tugandstand-byactivitiesforJack-upvessels

andOilrigs.WhatisspecialabouttheAnna-Bisthatitis

equippedonlywithazimuththrusters.Inthebowthere

aretwoelectricallydrivenShallowDraftThrusters,typeZF

SDT4010FP.InthesternaretwoZFAT6311WM-FPWell

MountedAzimuthThrusterspoweredbydieselengines.

Thisresultsina32x12mvesselwithabollardpullofmore

than35tons,combinedwithanunsurpassedmaneuver-

abilityandDP2notationfordynamicpositioning.

Simplifying Maintenance Inspections–ZFMarineEurasiaisnowoffering

camerainspectionfortransmissionsandotherengineroomcomponentsasa

preventivemaintenanceserviceforshipandyachtowners.Thisnewtechnology

makesitpossibletoinspectthebearingsandgearswithoutdismantlingthe

gearbox.Thankstocold-lighttechnology,thehigh-resolutionpicturesshow

detailswhichcouldnototherwisebeseenwiththenakedeye.

School Boats for the Amazon – ThebattleagainstilliteracyinAmazonareahasmetanimportant

ally,ZFMarine.Theneedforastandardized,safevesselformovingstudentsalongtheAmazoncanbe

proveninthenumbers.Theilliteracyindexcanreachmorethan30%insomeareas,mostlyduetothe

inabilityofthestudenttogettoaschool.Thefewboatscurrentlyavailabletakehourstocompletethe

variousschoolroutes.TheFDNE(theBrazilianfundfornationaleducationaldevelopment)hasrecently

takenonthechallengeofgettingyoungpeopleandteachersbacktoschool.RecentlyZFdoBrasil

completedthesaleofthefirst200gearboxesforaprojecteventuallytotaling700units.Theprojectwill

supplyafleetofnew29and49passengerschool-boatstoserveruralandriversidecommunitiesalong

theAmazonwheretheonlymeansoftransportisbyriver.

Austal’s Latest Ferry – HighspeedshipbuilderAustalhasrecentlydelivered

thelatestiterationoftheirAutoExpressferryrange,an80mRoPaxcatamaran

toFrenchPolynesianoperatorSNCAremitiFerry.TheAremitiFerry2cancarry

upto146carsand967passengers.PropulsioncomponentssuppliedbyZF

ServicesAustraliaincludeZF7640Transmissionsand3stationClearCommand

controlsystem.Austalsaysthenewgenerationvesselprovidesimprovedfuel

efficiency,lowermaintenancecosts,andimprovedtravelercomfort.

North AmericA

eUroPe eUrASiA

SoUth AmericA ASiA PAciFic

News from the RegionsNews from the Regions

76

Galactica Star: TEChNICAL ELEGANCE IN DESIGNAmegayachtisatonceaprecisioninstru-

mentandashowcaseofcomfortandluxury.

Thelatterfunctions,comfortandluxury,depend

ontheprecisionofthevessel’sdesign.

The65-meteraluminumyachtGalactica Star

epitomizesthisblending.

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Guests enjoying the elegant appointments of the living spaces will not concern themselves with the precision instrument that supports it all. But it is in this instrument that some of the vessel’s most elegant design can be found. The Dutch builder, Heesen Yachts is noted for the technical sophistication of their vessels. As the larg est yacht that Heesen has built to date, they began with a blank slate and designed the hull from the keel up.

Perry van Oossanen, of the firm of naval architects that bears his family name, explained the concept behind the Fast Displacement Hull Form (FDHF), “A round bilge hull performs well at low speed, but as soon as you want to go faster a hard chine hull is more efficient,” he explains. “I was certain we could find a better compromise. We started with a blank sheet of paper and when our first results produced over 20 per cent less resistance, compared with a hard chine hull, I realized straight away that we were on to something.”

Finding the balance between high speed and slow speed efficiency is made more challenging when the design is the first of its kind. Without existing vessels to prove

the design, Van Oossanen and the Heesen technical team relied on an array of modern technology. Computer Assisted Design has served architects well for some time now, but it is the Computational Fluid Dynamics (CFD) programs that can lend the equivalent of generations of design knowledge to a project. By translating the flow of water around the hull into millions of cells, CFD ana­lyses each cell individually to provide data on resist­ance, flow dynamics, how the hull sits in the water, and much more. In a computerized model, efficiency­ robbing cavitation and wave resistance can be identified at any speed and adjustments made accordingly.

With the virtual FDHF hull, complete with a dramatic bulbous bow, designed and proven on the computer, Hans Boerakker, Production Director at Heesen Yachts, wanted to see the visual evidence in a tank test. “After we completed the tank testing for the 65-meter at the Wolfson Unit in Southampton, they didn’t believe the final results,” Perry van Oossanen recalled, “They

thought there had been an error and ran the model again. We then asked for a quantitative comparison with their database and our model proved to be 30 percent more efficient on average than any equivalent hull at speeds in excess of 15 knots up to 44 knots. In other words, it was the most efficient displacement hull they had ever tested.”

Along with Finite Element Analysis (FEA) the desig­ners were able to create a hull form that is as elegant in performance as it is in

appearance. The hull also had to support a range of luxury appointments that added further challenges. In the for­ward section, two gull­wing doors would provide access to storage bays for tenders. An early consideration would have painted these doors black to replicate windows. But this can cause heat absorption resulting in uneven ex­pansion of the aluminum. Fortunately the design looked better with the doors painted the same light reflecting white as the rest of the hull. Such detailed attention is not dis­similar from the design of an elegant sports car, but this one is 65­meters long by 11.3­meters wide.h

“Inotherwords,itwasthemostefficientdisplacementhulltheyhadevertested.”

Cover StoryCover Story

report Marine Propulsion Systems 1.2014

report Marine Propulsion Systems 1.2014 98

Cover Story

Literally thousands of other choices and decisions go into the creation of a super­yacht like the Galactica Star. Some, like the finishes in the accommodation area, are purely cosmetic and so are determined by good taste. Others, like the form of the FDHF hull are determined by negotiating a set of compromises defined by the efficient movement of the hull though the water at various speeds.

Of course those speeds will be determined not only by how the hull moves through the water, but also by the power and weight of the engines and their gears. An advantage of the highly efficient hull form resulting from the careful design aided by the Computational Fluid Dynamics was that less power was required to meet, and exceed, the con­tractual 27­knot top speed. This, in turn, allowed lower noise levels for the owners and guest when cruising.

The engines selected to form the center of this elegant creation are a pair of MTU 20V 4000 M93L diesels each delivering 4300 kW (5766 HP) at 2100 RPM. The MTU factory ships these high performance engines with transmissions from ZF Marine to efficiently put the po­wer into the water. Heesen Yachts undertook a compa­rative study that found, “between Galactica Star and a selection of other motor-yachts of between 60–70 meters launched after 2000, reveal that she is able to achieve higher speeds with less propulsive power thanks to her efficient Fast Displacement Hull Form and aluminum construc tion. This means lower fuel consumption and

lower operational costs, while less bunker capacity frees up more space for other services or guest use and smaller engines help to reduce noise and vibration.”

“We are proud to be part of this outstanding project. The Galactica Star is truly a remarkable design. ZF trans-missions and bow thruster certainly play an important role in supporting the vessel’s ability to achieve these fan-tastic results. Our equipment fulfills Heesen’s performan-ce requirements for low weight and compact dimension for the given power. The owner of this amazing vessel will benefit from the reliability of our products and the ability to support him wherever the Galactica Star takes him.” said André Koerner, ZF Marine’s Head of Product Line, Commercial and Fast Craft.

Forfurtherinformationgotowww.heesenyachts.nl

TEChNICAL SPECIFICATIoNSHulltype:FastDisplacementHullFormNavalarchitect:VanOossanenNavalArchitects/HeesenYachtsExteriorstyling:OmegaArchitectsConstruction:Aluminium

DIMENSIoNS Lengthoverall:65.00m/213ft2inBeamoverall:11.30m/37ft7inDraught:3.10m/10ftWaterlinelength:57.5m/157ft2inGrosstonnage:985gt

TEChNICAL DETAILS Maximumspeed(50%load):27knotsRangeat14knots:4,200nauticalmilesFuelcapacity:90,000litres/23,770USgallons

PRoPuLSIoN DETAILS Mainengines:2xMTU20V4000M93LMaximumpower:2x4,300kWGearbox:2xZF23560CBowthruster:ZFTT2001FPALU–L-drive,electricallydriven

GALACTICASTAR

Facts and Figures

Cover Story

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...transportedprobably20drybulkproductslikefoodorrawmaterialsyouusedtoday.

...willberetiredfromthefleetby2019indicatedbyananalysisofthe2011U.S.Boatregistrationreport;approximately30%ofthesewillbeInboardengineconfigurations.

500224,572 SEAFARERS

WoRLDWIDEBoATS

...shippingcontainersarelosteachyearatsea,reportsWorldShippingCouncil.

...intheworldhavenomeansofcommuni-cationwhiletheyareontheopensea.

Only1in10willhavefreelyavailableInternet.

...(92ft)aregoingtobebuiltworldwidefrom2014to2017,according

tothecurrentorderbooks.

...isthelengthoftheworld’sbiggestsuperyacht,theAzzam,whichisownedbytheroyalfamilyoftheUnitedArabEmirates.Atonly7.35m(24ft)ontheotherend,thefunnylookingJetCapsule(presentedin2014byLazzariniDesign,Italy)doesnotseemtobeacompetitionfortheAzzam.

180 METERS(590FT)

2/3

350

oF ShIP CREW

SuPER yAChTSoVER 28 METERS

...thereare~1,650activeShipyardsinChina;about25%ofallcommercialvesselsproduced

inChinain2012wereworkboats.

1,650

238 048 Aktionslogo_V2.ai > ZF Marine > Frau Münch >2014-02-25 > LACON Marketing GmbH > Tel. +49-7543-9305-0 > CVE > 43x72 mm > 1:1 > Seite

report Marine Propulsion Systems 1.201410 11

News from ZF Marine Group

News from the Global ZF Group

Only hours before the drop of the green flag to start this year’s 24 hours of Daytona car race, ZF Friedrichshafen AG announced that it has become an official technical partner of the TUDOR United SportsCar Championship. The TUDOR Championship is the top sportscar category in North America and features 12 rounds at top racing venues throughout the U.S. and Canada.Around the globe, many renowned racing teams and car manufacturers have been relying on ZF's innovative tech­nologies and first­class service. From the top Formula 1 teams, Deutsche Tourenwagen Masters (DTM) competi­tors to the World Rally Championship and the 24 Hours of Le Mans, ZF helps race teams get to the winners circle. Through this new partnership with the TUDOR Cham­pionship, ZF is focusing its North American motor sports efforts towards the further development of this new sportscar series.

ZF Motorsport is a supplier of shock absorbers and clutches to the series. As the only link between the engine and transmission, durability to go the distance in an

This coming April, ZF Marine will be moving into a new facility in Shanghai. The facility will be jointly occupied by Marine and ZF Services, the service and parts divi­sion of the ZF Group. The new facility not only cont­ains office space along with training facilities, but also a warehouse and workshop space as well. Initially there will be a team of 7 employees in the marine office.

ZF BecomeS techNicAl SPoNSor oF tUDor UNiteD SPortScAr chAmPioNShiP

New locAtioN For ZF mAriNe iN ShANghAi

extremely harsh operating environment is key. At Dayto­na, drivers shift about 30 times a lap, and complete about 33 laps per hour. That equals almost 24,000 clutch engage­ments over the 24 hours of racing. That's a lot of shifts. To aid shifting, the car’s engine computer blips [revs] the en­gine to perfectly match the wheel speed on downshifts and on up­shifts it will cut the engine for a millisecond to enga­ge the next gear smoothly. ZF engineers tailor the clutch technology to the individual desires of each race team to help get them to the checkered flag and victory lane.

FASTER, hIGhER, STRoNGER!

The Aftersales & Service Managers of ZF Marine are ready to go, as the boat in

the background shows (“Vorwärts” is the German word for “Going forward”).

Left to Right: Wolfgang Götz (CFC Transmissions), Jurgen ostheimer (CC Thruster Systems),

Gianni D´Incau (PC Applications), Marc Sommer (ZF Marine head of Aftersales & Service).

They will be responsible for Market Development, Sales, Logistics, and Service and Parts support for all of ZF Marine’s product family in China. The small team will certainly be kept busy meeting the needs of the market, but has the support of the ZF Services group in the regi­on initially. The team will definitely grow as ZF Marine increases its customer base in the region.

Parts and Service

With the 2014 winter Olympics fresh in our minds, the Olympic motto of “Faster, Higher, Stronger” can also be applied this year to ZF Marine. For 2014 the Aftersales & Service team has launched the “Year of Service”. During this campaign ZF Marine will invest additional efforts and resources to launch initiatives that will have a noticeable positive impact on customer service. One thing is clear, downtime frustrates an operator. Deadlines or sailing schedules cannot be met or a day on the water with family and friends gets cancelled. Whatever the case, the value of fast, quality service is paramount. Well planned, high quality maintenance and service contributes to the longest lifetime and highest value of a vessel, regardless if it is a commercial craft, high speed ferry or motor yacht.

What are our keys for improvement?

Fast solutions: Bring factory backed parts and service closer to our customer to be ready when they need us. Where it’s needed, we’ll establish additional local com­petence centers with local parts stock, service staff, and market expertise ready to serve our customers. ZF Marine support – in the same time zone, speaking the same lang­uage, when and where you need us.

High Availability: ZF Marine is reorganizing their dedi­cated aftersales warehouses to implement an optimized stocking strategy at each of the global Product Com­petence Centers in Krimpen, Netherlands, Arco, Italy,

and Friedrichshafen, Germany. If a part isn’t on the shelf at a Global Competence Center, a new global stock sha­ring arrangement will allow us to see where a part is and get it moving to where it’s needed right away.

Strong Aftersales & Service Network: By investing in our people and equipment to help them do their jobs well, our international service staff can ensure that ZF Marine is not just locally present, but ready to provide immediate service solutions to our customers. We have reorganized and standardized our training courses and will have state of the art training centers in each Product Competence Center by the end of the year. In addition, we transfer the know­how of the product experts to our Regional Competence Centers to ensure that product ex­perts for each system are available in each and every region. To be on the spot in large metropolitan markets, we are planning to implement “ZF Marine Aftersales and Service Points” for routine maintenance and small service jobs in the pleasure craft segment. Independent marine workshops located close to harbors or marinas will be trained to maintain our pleasure craft products. It goes without saying, they will use original ZF parts and know who to contact at ZF for technical support.

ZF Marine Propulsion Systems supplies a complete line of commercial transmissions, thrusters, propellers and control systems, offering the maneuverability, dependability and operating speed the marine industry requires. A global customer service and after­sales support is availble on demand. www.zf.com/marine

ZF is ProPulsion.

ZF Marine Propulsion Systems supplies a complete line of commercial transmissions, thrusters, propellers and control systems, offering the maneuverability, dependability and operating speed the marine industry requires. A global customer service and after­sales support is availble on demand. www.zf.com/marine