To achieve net zero by 2050, as recommended by the International Maritime Organisation (IMO) and supported by the UK Department for Transport, decarbonising the maritime industry is vital. But like in many industries, it is no simple task. It requires the scaling up of renewable fuels, transforming ship design and will demand innovation and collaboration.
We have demonstrated how this can be achieved through our collaboration with Anemoi, a global provider of proven wind technology that is delivering a more sustainable future for the shipping industry.
Harnessing the wind to provide auxiliary propulsion to vessels is not a niche concept but is a proven way to reduce fuel consumption and emissions. This technology of Rotor Sails, believe it or not, was first installed on ships in the 1920s and they were originally known as Flettner Rotors in recognition of their inventor, Anton Flettner.
The Rotor Sails are tall, mechanically driven cylinders which spin to harness the power of the wind and create additional thrust for a vessel. By supplementing the ship’s main propulsion system, Rotor Sails can help reduce engine load, fuel use and therefore associated emissions.
There are of course other wind propulsion technologies such as traditional sails or wings, but the Rotor Sails offer a much greater thrust force to propel the ship per square metre of sail area. And to further support the ease of day-to-day vessel operations, Anemoi provides three deployment systems; fixed, rail and folding.
For bulk carrier vessels where Rotor Sails may need to be repositioned so that cargo handling equipment can operate without obstruction, a folding or rail system is recommended to enable the sails to be moved safely either upright or lowered from vertical to horizontal using a hydraulic system.
A demanding engineering challenge
However, for smaller vessels or those with complex cargo operations an alternative solution to folding beams was required where space and safety could be an issue, hence the rail system was developed by Anemoi. The challenge lay in the repositioning system requiring battery-powered motorised trolleys capable of moving the substantial weight of the Rotor Sails, in an upright position, while operating reliably in a harsh marine environment. The application also called for precise control, dependable power transmission and the flexibility to meet a detailed functional specification. This is where our expertise was called upon to develop a bespoke solution to power the trolleys.
Rather than supplying a single component, the project required a complete remote-controlled transmission system. Each trolley required a gearbox and motor to drive all four wheels. The solution also required a controller and software to coordinate the system’s operation.
Drawing on our product knowledge and extensive supplier network, we sourced high-quality gearboxes and motors and integrated them into a prototype system. The system was initially trialled at our on-site test bed, enabling thorough testing and troubleshooting in a controlled environment before working closely with Anemoi’s engineers at its site. This collaborative approach enabled both teams to refine the system against robust real-world requirements, from load handling and drive performance to control response and operational reliability.
A critical part of the project was the software and control system. We developed the software to meet the machine’s functional specification, then refined it throughout the project to optimise trolley operation.
The project also reflects wider trends in electrification surrounding the need for controllers that can manage more complex systems, integrate with multiple machine functions and meet the higher legislative expectations around diagnostics and safety. This is where the F-series of controllers come into play, they are aligned to the trend direction of electrified equipment and support the move towards advanced diagnostics, functional safety considerations and system-level integration.
In practice, this means that control architecture can be seamlessly integrated as part of a complete solution, rather than be an isolated add-on. For demanding applications this approach helps ensure the mechanical, hydraulic, electrical and software elements all work together as one coordinated package, able to handle more complex applications. And for Anemoi, this approach was central to the success of the system.
The project has demonstrated how bespoke powertrain systems and intelligent software controls can help turn sustainable maritime technology into a practical operational solution.
Have a project you need support with? Get in touch with our team.