Data-Driven Optimization of Voith-Schneider Tug Operations: Towards a Digital Twin Framework for Port Energy Management

Abstract

[Abstract] This study presents a data-driven methodology to optimize the operational efficiency of a tugboat equipped with a Voith-Schneider Propeller (VSP) based on full-scale fuel consumption and vessel performance data. The objective is to identify optimal combinations of engine RPM and propeller pitch to reduce fuel consumption during low-demand phases without compromising maneuverability. Sea trials were conducted under controlled conditions using a dual flowmeter system and onboard speed measurements. The data enabled the construction of performance curves, efficiency ratios, and interpolated maps of fuel consumption. Optimal configurations were identified across defined speed ranges, and continuous efficiency zones were visualized through iso-consumption and contour plots. The results reveal a nonlinear relationship between propeller pitch, speed, and fuel demand, with maximum efficiency occurring at medium-to-high pitch values and speeds between 3 and 6 knots. This methodology provides a replicable tool for energy management in port operations and supports informed decisions during accompanying operations and standby periods. Efficiency differences over 300% between RPM–pitch settings were found, highlighting the operational impact of informed configuration choices. Moreover, the structured dataset and visual analysis framework lay the groundwork for future digital twin models aimed at enhancing operational efficiency in VSP-powered tugboats.