Old power supply systems in maritime technology present certain challenges
It became apparent in a naval underwater unit that the existing electrical power supply systems were increasingly affected by ageing and obsolescence. The aim was to extend their service life by around 10 years to ensure operational readiness until new underwater platforms were introduced.
The challenges lay in meeting the high demands for reliability under maritime conditions, integrating modern electronics into existing installations, reducing weight and avoiding costly structural modifications. The original system included complex, interconnected power supply systems that were inefficient and maintenance-intensive due to the technology in use. The aim was to replace it with modern, digitally controlled systems that would offer improved efficiency and easier handling.
Reliable energy supply under extreme maritime conditions
Thanks to intelligent safety software, continuous monitoring and a redundant system architecture, the modernised power supply system offers maximum operational reliability. All components comply with international maritime safety standards and are prepared for future regulatory requirements in the field of German maritime shipping.
The system provides a stable power supply, even in extreme environmental conditions such as salt water, vibrations, pressure and temperature fluctuations. Real-time monitoring, fault detection and automated protection mechanisms minimise the risk of failure and ensure the system remains operational in the long term.
Improved performance through embedded systems and digital interfaces
Modernisation increased the performance of the power supply while reducing energy losses. Real-time-capable embedded systems and digital interfaces, such as Ethernet and Modbus TCP, enable seamless integration with existing on-board networks, monitoring systems, and maritime IoT/fleet management software.
Intuitive operation and visualisation via human-machine interface (HMI)
The human-machine interface (HMI), which is based on a TFT touch display, enables operating personnel, engineers and technicians to control and visualise all measured values and warning messages intuitively and clearly. This reduces operating errors, shortens training times, and improves operational efficiency in the long term.
As part of the HMI development process, technical diagrams and flowcharts were created prior to implementation to optimise the structure of the operating logic and menu navigation. These include:
- This HMI system overview shows the main functions, data flows and interfaces
- Dependency relationships between screen menus and control elements are visualised through flowcharts
These designs formed the basis for subsequent communication between the HMI and the control system via UART and DSPIC. This ensured stable, high-performance interaction with the system’s real-time control.
Seamless integration into existing vehicle electrical systems and control systems
The modernised system was fully integrated into the existing cabinets and installation environments. This meant that costly modifications could be avoided. The solution is compatible with the on-board power supply and higher-level control and monitoring systems, enabling smooth operation and the rapid implementation of new functions. It supports digitalisation in modern shipbuilding and enhances the platform’s long-term operational capability.
Precise energy conversion, diagnostics and predictive maintenance
The power supply provides all the essential voltage ranges (400 Hz, 60 Hz, 24 V DC), with load distribution between the systems being synchronised. A powerful digital signal processor (DSP) controls all converter functions in real time to ensure precise voltage and current regulation.
The integrated diagnostic system continuously monitors safety-related parameters, detects deviations, and automatically initiates protective measures. Data is clearly visualised via the HMI and can be integrated into higher-level monitoring systems via Ethernet or Modbus TCP, providing a basis for predictive maintenance in the maritime environment.
Modern embedded technologies and comprehensive quality assurance
The software is based on embedded systems comprising microcontrollers and digital signal processors (DSPs), and was developed using the C/C++ programming languages to ensure real-time behaviour and maximum performance.
The HMI was created using uniTFTdesigner and boasts modern GUI designs and optimised touch interactions. Quality assurance involved hardware-in-the-loop (HIL) tests, module tests and integration tests, which were used to test functionality and real-time responses under realistic conditions.
The developed software architecture is characterised by a clear separation of logic, visualisation and hardware. This modular structure minimises errors, allows the development team to work in parallel and ensures the software can be easily reused in future projects.
Hybrid development process for flexible and secure project implementation
The project adopted a hybrid development model, combining the strengths of traditional and agile approaches. A structured approach based on the V-model was adopted for safety-critical functions, and agile iterations were used to enable the flexible further development of the HMI software.
The process covered all phases of systems engineering, from requirements analysis and architecture to design, implementation, integration and comprehensive system testing, culminating in final acceptance.
Thanks to regular review cycles and close coordination with the customer’s technical contacts, the project team could adapt requirements quickly and implement them in a practical manner. Several joint workshops were held to optimise operating concepts and graphical user interfaces, highlighting the collaborative and solution-oriented approach.
Increased availability, energy efficiency and simplified maintenance
The new solution has been successfully installed and is now operational under real conditions. It includes modernised energy supply systems and fully integrated software modules, as well as all the associated documentation.
The advantages are measurable:
- Greater reliability and availability, even under heavy loads.
- Weight reduction of around 700 kg, which improves both efficiency and energy consumption.
- Reduced maintenance costs thanks to digital diagnostic functions.
- Simpler operation thanks to intuitive HMI design.
- Longer system life. Lower overall costs.
The solution supports the digitalisation of the maritime sector, enhances operational capability, and establishes the foundation for the expansion of strategies for supporting critical maritime systems.
Documentation and technical diagrams
Several technical illustrations and architectural sketches were created during development to clearly document the structure and functionality of the entire system.
- The overall structure of the power supply system is shown in the system architecture diagram. This diagram includes inverters, rectifiers and communication interfaces.
- The power conversion block diagram shows the flow of energy from the input source, via converters, to the output voltages (400 Hz, 60 Hz and 24 V DC).
- The Control and Monitoring Architecture describes the interaction between control, HMI and sensor technology, including communication channels via UART and DSPIC.
- Hardware Integration Diagram: illustrates the mechanical and electrical integration into existing control cabinets (retrofit integration).
These documents were used for internal coordination and technical documentation for the client. They were an integral component of system engineering, facilitating traceability and ensuring the quality of the development process.
Scalable solution for marine, shipbuilding and offshore projects
Plans are in place to expand the platform with IoT functions in the future. The aim is to integrate additional monitoring and analysis capabilities to enable predictive maintenance, allowing the solution to be used in other areas of inland and maritime shipping, as well as in shipbuilding and offshore systems.
Successful modernisation of the power supply
Konzept Informationssysteme has successfully completed this technologically demanding project in the fields of maritime software, ship technology and embedded systems.
The solution meets the highest safety, efficiency and usability requirements. It extends the system’s service life, reduces operating costs and increases operational readiness.
Thanks to its modular, reusable architecture, the system is future-proof and can be transferred to other marine platforms — an important step towards sustainable maritime digitalisation and technological leadership in modern shipbuilding.
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