www.hpmag.co.uk HYDRAULICS & PNEUMATICS November/December 2025 35 the system could act instantly. Vibration is a red flag, as it only ever gets worse.” The system architecture was designed to be both compact and efficient. Beckhoff’s EtherCAT P modules allowed the analogue-to-digital conversion to take place close to the sensors, reducing signal noise and simplifying the wiring. All data acquisition, control logic and visualisation tasks ran on a single industrial PC, avoiding the need for multiple systems. “We bundled everything - control, analytics, vision and HMI - into one IPC. That level of integration isn’t typical,” said David Grice, software applications engineer at Beckhoff UK. Flexible benefits From Penty’s perspective, the key benefit of choosing Beckhoff was its flexibility. “It allowed us to encapsulate the entire hardware scope with one solution. The open architecture made it easier to integrate third-party components, including the customer-specified ABB drive and motor and certified marine sensors.” One unexpected challenge was aerodynamic drag. The test rig structure, unlike a real rotor sail, was open for easy access to internal components. However, this exposed steel frame created more drag than the real Rotor Sail, limiting the rig’s top speed. “We added aerodynamic fairings to the structure to mimic the smooth shape of a real sail. That cut drag significantly and allowed us to reach full test speed,” said Penty. Other innovations included traction control logic for the tyre drive. The software is able to detect any loss of grip that might be experienced in wet conditions, and automatically reduces drive torque to prevent slip. According to Penty, these refinements help ensure the rotor sail system is practical and serviceable at sea. “Ships can go five years without returning to the shipyard for scheduled maintenance. In the unlikely event something fails, it has to be fixable by a marine engineer on board. That’s why Anemoi have kept the design as simple and rugged as possible, while optimising efficiency for maximum savings in fuel consumption and emissions.” Automation and sustainability Rotor sails are already helping shipowners reduce emissions, but automation is critical to accelerating adoption. With Beckhoff’s technology stack, engineers at Anemoi can monitor complex dynamics Looking to source fluid power systems and equipment? www.hap-guide.com Interactive Buyers’ Guide website and test under controlled, repeatable conditions. “It’s all about validating and trusting the data,” Ragdale added. “When you’re running test cycles that last ten hours, you need to know your system can capture everything reliably.” For this project, testing is now complete and the first Rotor Sails using these components are in production, although the test rig will continue to provide useful data for future designs. Looking ahead, the team sees broader opportunities for automation to support sustainability goals in marine and renewable sectors. According to Grice,”we’re seeing increased demand for test benches and condition monitoring across wind, subsea and hybrid marine technologies. The ability to combine high-performance control with real-time insight is a gamechanger.” For Anemoi, this project marks a step in the evolution of rotor sail technology. For Beckhoff and Pressure Design, it offers a compelling example of how integrated automation can drive forward innovation in sustainable engineering. For further information please visit: https://www.beckhoff.co.uk/
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