The marine industry is no stranger to challenges, particularly when it comes to developing components that can withstand the harsh realities of saltwater environments. Jesse Dupuis, Director of Powertrain Product Management at Regal Rexnord, recently highlighted a compelling case study that underscores the importance of innovation and collaboration in addressing these challenges. An international engineering technology company sought assistance in designing a marine winch, a crucial component used for controlling, lifting, and retrieving remote-operated vehicles (ROVs) like hull cleaners. These ROVs play a vital role in maintaining ship hulls, preventing biological contamination, and enhancing fuel efficiency.
Initially, the engineering firm found itself at a crossroads, unable to find a winch solution that ticked all the boxes. They had a concept in mind but were struggling with its complexity and potential maintenance issues. Enter Regal Rexnord’s Powertrain Solutions team, ready to roll up their sleeves and tackle the problem head-on. The goal was clear: simplify the design without sacrificing performance or reliability.
The design process was no walk in the park. The winch had to withstand high levels of corrosion from salt spray, fit into a compact enclosure, and meet specific torque and speed requirements for effective ROV operation. The team worked diligently to eliminate unnecessary components from the original design, reducing complexity by a staggering 58%. They axed seven components, including the synchronous belt and sheaves, and combined the motor, brake, and encoder into a single Kollmorgen servo motor. This move not only streamlined the design but also significantly reduced costs and weight.
The results were nothing short of impressive. By rethinking the design, the team managed to cut the overall cost of the winch system by 32% and reduce its weight by 13%. Reliability and efficiency saw a 3% boost, and maintenance became a breeze with the removal of components that typically struggled in salty conditions. The dynamic braking solution, which utilized the servo motor’s capabilities, provided both rapid response and redundancy, enhancing safety and operational efficiency.
This collaboration between the engineering firm and Regal Rexnord is a prime example of how innovative engineering can simplify complex systems. The benefits extend far beyond mere numbers; they include a 50% reduction in assembly time, lower logistics hassles by consolidating suppliers, and improved safety measures. The winch now boasts a design that not only meets the rigorous demands of marine applications but also exceeds the customer’s expectations.
As the maritime sector continues to evolve, this case study serves as a beacon for future developments. It illustrates the importance of collaboration in overcoming industry challenges and emphasizes the need for sustainable, efficient solutions. The lessons learned here could inspire other companies to rethink their designs and approaches, ultimately driving innovation across the marine industry. With the stakes so high—environmental sustainability, operational efficiency, and safety—there’s no doubt that forward-thinking partnerships will be the key to navigating the waters ahead.
