ZF is showing its condition monitoring system and the latest generation of the AutoTroll speed control, with an optional firefighting function for thruster-propelled vessels, at SMM 2026 in Hamburg from 1 to 4 September. The company is in Hall A3, booth 219, where it also displays its thruster and transmission technologies.
Condition monitoring pairs onboard hardware with cloud analytics to track drivetrain behaviour. Data from the gearbox electronics and connected sensors, covering speed, pressure, temperature and operating modes, is captured, processed and sent to a backend platform over secure mobile communication. ZF says the system supports condition-based maintenance, cuts downtime and improves fleet efficiency. For a proof-of-concept demonstration the company is working with Danish ferry operator Molslinjen.
"Operational efficiency at sea depends on more than propulsion power alone. It requires transparency, control and the ability to make informed decisions based on real data," says Florian Götz, Head of Sales Commercial and Fast Craft at ZF. "With our condition monitoring system, we help operators to better understand their drivetrains, optimize performance and contribute to safe and predictable operation over time."
AutoTroll 2 uses a closed-loop control system that adjusts propeller speed faster and more accurately than the previous version. ZF cites docking manoeuvres and dynamic positioning work as the main use cases. Operators choose between five shifting characteristics, from a very smooth response, for instance when slowly following a swarm while fishing, to more direct behaviour, for instance when showing a sport yacht's engine power. A single setup covers conventional and DP trolling modes, and parameters such as allowable engine speed are adjusted automatically depending on the operating mode to protect drivetrain components.
Communication runs over CAN. ZF points to reduced wiring effort and the option to exchange diagnostic and status data between systems. The system is designed to meet current cybersecurity requirements for electronic control units in maritime applications.
The firefighting function is an optional AutoTroll extension for thruster applications. It commands speed during firefighting operations with fixed pitch propellers, using a clutch slip design that lets the engine reach the maximum speed needed to drive the ship's monitor pump without passing that speed to the shaft line. The vessel keeps its manoeuvrability while the firefighting equipment runs. Additional sensors, cooling concepts and control functions handle the higher thermal load on drivetrain components during these sustained operations.
Bringing propulsion control and firefighting into one system architecture reduces the need for separate solutions on board. The function is available for all AT WM thruster sizes from the ZF AT 40 upwards.