Precision, performance, persistence: ZF highlights condition monitoring and advanced propulsion control at SMM 2026

Modern vessels are expected to operate with a high degree of precision, often in constrained environments and under continuously changing conditions. Whether during harbor maneuvers, offshore operations or emergency situations, controlling propulsion output accurately while keeping systems within safe operating limits is critical. As propulsion systems become more powerful and interconnected, the ability to both monitor system health and fine-tune behavior in real time is becoming a key differentiator in vessel operation.

That’s why at this year’s SMM, ZF is not only highlighting its newest drivetrain solutions, but also its condition monitoring system and the latest generation of AutoTroll speed control including its optional firefighting feature for thruster-propelled vessels.

Condition monitoring: Where performance meets reliability

“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.”

For this reason, ZF is partnering with Danish ferry operator Molslinjen for a special proof-of-concept demonstration of its condition monitoring system. The system combines onboard hardware and cloud-based analytics to provide continuous insights into drivetrain behavior. Data from the gearbox electronics and connected sensors, including speed, pressure, temperature and operating modes, is captured, processed and transmitted to a backend platform via secure mobile communication. This supports condition-based maintenance, reducing downtime and improving fleet efficiency.

AutoTroll 2: Precise control for complex operations

Moving fast is easy. Keeping vessels under full control at low speeds while avoiding unnecessary strain on the drivetrain is more demanding. This is where ZF’s AutoTroll 2 can display its strengths.

AutoTroll 2 allows for both more precise and more adaptable control than the previous version, with its closed-loop control system ensuring faster and more accurate adjustment of propeller speed. This improves handling during maneuvers such as docking or dynamic positioning (DP) operations.

Operators can select between five different shifting characteristics, ranging from very smooth response (e.g., when slowly following a swarm during fishing) to more direct, dynamic behavior (e.g., when showcasing a sport yacht’s engine power). The system also supports both conventional and DP trolling modes within a single setup. Depending on the operating mode, parameters such as allowable engine speed are adjusted automatically to protect drivetrain components and ensure reliable operation.

Integration into modern vessel architectures is simplified through CAN-based communication, reducing wiring effort while enabling additional diagnostic and status data to be exchanged between systems. At the same time, the system is designed to meet current cybersecurity requirements for electronic control units in maritime applications.

AutoTroll Firefighting: Persistent command in emergency situations

As an extension of AutoTroll, ZF is presenting an optional firefighting function designed specifically for thruster applications. The system provides precise command of speed during firefighting operations for fixed pitch propellers. The key is a specialized clutch slip design that can accommodate the maximum engine speed (used to drive the ship’s monitor pump) without transmitting this full speed to the shaft line. This allows vessels to operate firefighting equipment while maintaining maneuverability and system stability – even when the drivetrain is exposed to sustained high loads.

Additional sensors, cooling concepts and control functions help manage the increased thermal load on drivetrain components during such demanding operating scenarios. This prevents overheating and supports long operating times without compromising component integrity.

By integrating propulsion control and firefighting functionality within a single system architecture, AutoTroll Firefighting reduces the need for separate solutions and simplifies system coordination on board. This supports safe and efficient vessel operation in critical missions where reliability and responsiveness are essential. The feature is available for all AT WM thruster sizes from the ZF AT 40 and larger.

Find ZF at SMM 2026

Visitors to SMM 2026 can learn more about the full range of ZF’s maritime portfolio in Hall A3, booth 219.