With automatic drive systems, ships use 40% less fuel

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What was needed? Alternatives to metallic solutions that are lightweight, low-maintenance and perfectly able to withstand loads at low speeds
Requirements: Wing sails can be rotated 360°, high environmental requirements such as a wide temperature range, high humidity, seawater, water waves and high possible wind speeds
Industry: Shipbuilding industry
Success for the customer: Despite green technology on the high seas, the application was very specialised and igus® provided comprehensive project support in the selection of the bearing components. The ball and plain bearings have been operating at maximum performance without any failures since installation.

bound4blue supplies automatic wind-assisted propulsion systems (wingsails) that utilise renewable energy for all ship owners and operators who want to reduce their fuel costs and pollutant emissions and save up to 40% of fuel consumption. The shipping industry is a massive polluter and is faced with costly emission reduction regulations that present it with a double challenge: Fuel consumption accounts for between 30 and 60% of a ship's operating costs, depending on fuel costs and ship type and size, and shipping is a major contributor to global CO2 emissions as well as nitrogen oxide (NOx), sulphur oxide (SOx) and particulate matter (PM10) emissions, which are much more harmful to ecosystems and human life (acid rain, greenhouse effect, cardiovascular diseases, etc.).

Two complementary propulsion systems have been developed that are fully automatic and fully adjustable to adapt to any wind situation. They enable fuel savings of up to 40 %. One of them can be completely folded down onto the ship's deck. These systems are designed as additional propulsion for maritime transport and generate effective thrust from the available wind, an affordable and clean source of energy.

Problem

Use on the high seas requires components that can withstand the severe weather conditions. Conventional metal plain and ball bearings are absolutely unsuitable due to the high risk of corrosion. For the first application, the Pitot sensor system, the main requirements are corrosion resistance in marine environments, low weight and inertia. For the second application, the main requirements are resistance to the load caused by the gearbox and the system loads, as well as suitability for heavy weather conditions at sea.

Solution

Plastic ball bearing BB-6004-B180-30-ES was used as the solution of the first application due to its high corrosion resistance and light weight. It was used as the main bearing of the pitot system (instrument for measuring atmospheric pressure), which is an important sensor of the wing sail system. As a solution of the second application, plain bearings with flange XFM-4044-40 were used due to its corrosion resistance. It was used in all gear shafts and support rods of the flap subsystem, which is absolutely crucial for the activation and movement of the wing's flap system.

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