ZF Friedrichshafen AG, 2011

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1 All data and information provided are believed to be accurate and reliable and represent the available information at the the highest degree of accuracy possible and limited to the purposes of general information. Data, drawings and information are the property of ZF Group/ZF Marine and may not be copied or disclosed except by written agreement.

2 From Concept to Sea: ZF Marine development of ZF POD 4000, co-design with shipyards and efficient drive integration into pleasure crafts. Paolo Di Muro, ZF AG, BU Marine ATENA Conference, Politecnico di Milano, 3/6/13

3 SUMMARY ZF Group and ZF Marine Propulsion Systems ZF POD Drives range ZF POD Drive applicability range ZF and ZF POD range POD drives: competitive advantage vs shaftline POD Drives ZF POD drives. Co-design with shipyards. Activities ZF POD drives. Co-design with shipyards. Targets Co-design with shipyards ZF 4000: key figures ZF POD 4000: hull integration Patented suspention system ZF POD 4000 Sea trials Test results AZ 62s MCY 76 Seatrials-Results BU Marine 1/30

4 SUMMARY ZF Group and ZF Marine Propulsion Systems ZF POD Drives range ZF POD Drive applicability range ZF and ZF POD range BU Marine

5 ZF Group Ferdinand Graf von Zeppelin ( ) German inventor, airship designer and founder of ZF Friedrichshafen AG in /30

6 ZF Group 2012 Facts & Data Sales Mio Employees R&D expenses per year, Consolidated ZF Group in million 121 production companies and 8 main development locations in 27 Countries BU Marine 3/30

7 ZF Marine ZF Marine is part of Division I of ZF Friedrihshafen AG and operates in Pleasure, Commercial and Fast Crafts segments. 4/30

8 ZF POD Range (Gearbox) (Gearbox) DEPARTMENT BU Marine 8 ZF POD Drives: electro-mechanic comprehensive systems 5/30

9 ZF POD Range ZF Series 2000 ZF Zeus - ZF Series 3000 ZF Series 4000 Torque and Power DEPARTMENT BU Marine 9 6/30

10 ZF POD Range Integrated steering Upper unit Input flange (mechanical connection to engine) Lower unit (gearcase) ZF Series 4000 DEPARTMENT BU Marine 10 Pushing contra-rotating propellers 7/30

11 ZF POD range. Open engine frame* KW range * Refer to «ZF Product Selection Guide» for detailed values ZF POD 2000 ZF POD 3000 DEPARTMENT BU Marine 11 ZF POD /30

12 Applicability range*. (twin plants only are shown) Cruisers Luxury Yachts Displ. [ton] Day and sport cruisers ,0 52,5 45,0 37,5 30,0 Sport Yachts ,5 15,0 ZF 3000 ZF ,5 ZF *Average-based and trend graph. Detailed analysis available from ZF Marine Propulsion Application Office DEPARTMENT BU Marine 12 Power [kw] 9/30

13 SUMMARY ZF Group and ZF Marine Propulsion Systems ZF POD Drives range ZF POD Drive applicability range POD drives: competitive advantage vs shaftline POD Drives BU Marine

14 POD drives.competitive advantage Driveline Resistance reduction (lower unit design) S [m 2 ] C D Shaftline PODs DEPARTMENT BU Marine % of bare hull 7-10% of bare hull 10/30

15 Recovery of rotational energy (contra-rotating propellers) POD drives.competitive advantage η 0, , Rotational and viscous losses. Example. J.H. de Jong, MARIN Shaftline PODs Thrust optimization: angle from 10/14deg to 0deg above BL, i.e. parallel to keel Thrust optimization: thrust deduction factor reduces (larger tip clearance, lower propeller/ hull interaction) Wake fraction reduction (lower unit profile, reduced propeller-induced flow swirl) DEPARTMENT BU Marine 15 11/30

16 SUMMARY ZF Group and ZF Marine Propulsion Systems ZF POD Drives range ZF POD Drive applicability range POD drives: competitive advantage vs shaftline ZF POD drives. Co-design with shipyards. Activities ZF POD drives. Co-design with shipyards. Targets Co-design with shipyards BU Marine

17 ZF POD drives.co-design with shipyards Activities NAVAL ARCHITECTURE Weight and CG analysis Engine room lay-out Tunnel development Resistance analysis Trim analysis PROPULSION Power prediction Speed prediction Propeller selection SETTING UP Low-speed manouverability High-speed manouverability Mooring and side movement DEPARTMENT BU Marine 17 12/30

18 ZF POD drives.co-design with shipyards Targets NAVAL ARCHITECTURE POD-oriented hull design Fulfillment of safety and maintenance requirements PROPULSION Cruise/top Efficiency Thrust Planing capability SETTING UP Comfort Safety Friendly and Customized use DEPARTMENT BU Marine 18 13/30

19 SUMMARY ZF Group and ZF Marine Propulsion Systems ZF POD Drives range ZF POD Drive applicability range POD drives: competitive advantage vs shaftline ZF POD drives. Co-design with shipyards. Activities ZF POD drives. Co-design with shipyards. Targets ZF 4000: key figures ZF POD 4000: hull integration Patented suspention system ZF POD 4000 BU Marine

20 ZF 4000: key figures Push contra-rotating propellers ZF remote transmission Vertical installation Intermediate shafting (CV joint, membrane shafts, cardan shafts), customized ZF Controls (SmartCommand) operated by multiple stations Position keeping «Close loop» logic: self adaptive vessel behaviour (GPS + compass) Ratios: 1,985 2,212 DEPARTMENT BU Marine 20 14/30

21 ZF 4000: hull integration. DEPARTMENT BU Marine 21 15/30

22 ZF 4000: hull integration. Engine room Shaftline + ZF500-1A 7.0 m Shaftline + ZF500 IV 5.4 m ZF POD ZF500 DEPARTMENT BU Marine m 16/30

23 Patented suspension system Innovative and patented suspension system with structural GRP requirement about same as that typically required by Registers for shaftline applications. DEPARTMENT BU Marine 23 17/30

24 Patented suspension system Reaction Loads on POD mounts Loads on vessel stringers Vessel loads spreading to hull Propeller Thrust DEPARTMENT BU Marine 24 18/30

25 SUMMARY ZF Group and ZF Marine Propulsion Systems ZF POD Drives range ZF POD Drive applicability range POD drives: competitive advantage vs shaftline ZF POD drives. Co-design with shipyards. Activities ZF POD drives. Co-design with shipyards. Targets ZF 4000: key figures ZF POD 4000: hull integration Patented suspention system Sea trials Test results AZ 62s MCY 76 Seatrials-Results BU Marine

26 Sea trials - Test results Azimut 62s Montecarlo Yachts 76 DEPARTMENT BU Marine 26 19/30

27 AZ 62s with ZF POD 4000 Model Azimut 62S Type Sport Cruiser LOA / LWL [m] 18.4 / 15.7 BOA / BWL [m] 4.9 / 4.4 Design and Test 31.8 Displacement [t] Powerplant 2xCat C18 (1015HP) Max. Test Speed [kts] 36.8 DEPARTMENT BU Marine 27 20/30

28 AZ 62s with ZF POD 4000 Extensive CFD (2-DOF, RANSE) analysis anticipated and double checked sea trials. Tunnel effects were included in the analysis DEPARTMENT BU Marine 28 21/30

29 AZ 62s case: top speed comparison POD vs Shaftline: calculated 12% higher speed with same power and weight DEPARTMENT BU Marine 29 22/30

30 AZ 62s case: running trim angle Planing hump reduced and moved to lower speed DEPARTMENT BU Marine 30 23/30

31 AZ 62s case: fuel consumption, load Shaftline ZF POD ZF POD weight) Speed [kt] Consumption [l/h] Load [%] ~ calculated 17% fuel saving at same knots DEPARTMENT BU Marine 31 24/30

32 AZ 62s case: turns Shaftline vessel turns Cruise speed (31.0kt): 205.0m High speed (34.0kt): 405.0m ZF POD 4000 vessel* Cruise speed (32.5kt): 105.0m High speed (36.0kt): 90.0m ZF POD 4000 *Steering angle unlimited (controls deactivated, only mechanical stops) DEPARTMENT BU Marine 32 25/30

33 AZ 62s case: turns DEPARTMENT BU Marine 33 26/30

34 Model MCY 76 Type Yacht LOA / LWL [m] 23,0 / 18,85 BOA / BWL [m] 5,65 / 4,83 Design and Test 51.8 Displacement [t] Powerplant 2xMAN V (1200HP) Max.Test Speed 30.4 [kts] MCY 76 with ZF POD 4000 DEPARTMENT BU Marine 34 27/30

35 MCY 76 case: top speed comparison Shaftline: 2xMAN V HP* ZF POD : 2xMAN V HP** POD: same speed with 400HP less * Data source: «Nautica» (09.10) and «MBY» (10.11) ** Data source: ZF seatrials DEPARTMENT BU Marine 35 28/30

36 MCY 76 case: fuel consumption Speed [kt] Shaftline ZF POD ~ 20% fuel 30.0 knots DEPARTMENT BU Marine 36 Consumption [l/h] 29/30

37 Thank you very much for your attention! DEPARTMENT BU Marine 37