The B ZERO Auto Ballasting project was carried out by Hoppe Marine GmbH with the aim of developing an automated ballast‑water system that can set a predetermined trim by controlling the ship’s ballast tanks. The core of the effort was the design, installation and validation of a comprehensive sensor suite that feeds real‑time trim data into the vessel’s existing automation infrastructure.

At the outset, the demonstrator ship was inspected and a system architecture was drafted. The architecture was realised through a dedicated cabling plan that enabled the integration of additional on‑board sensors into the ship’s existing network. Three inertial measurement units (HOSIM) were mounted to capture angular rates and accelerations, while six GNSS receivers were positioned around the hull to provide cross‑validated vertical reference points. A power‑measurement rig on the drive shaft recorded shaft speed and torque, and a programmable logic controller (SPS) together with an embedded iPC (HOMIP) handled data acquisition, processing and logging. A separate server PC processed the GNSS data and linked it to the ship’s telemetry system. All subsystems were housed in appropriately protected enclosures and supplied with the required power.

The technical results demonstrate that the integrated sensor system can determine the ship’s vertical position with an accuracy better than 12 mm. This was verified by comparing the relative Z‑position of the bow and midship GNSS sensors against the ship’s known geometry. The data set also revealed outliers, which were filtered out to improve reliability. In addition, a comparison of a parabolic model with classical beam theory for a maximum deflection of 0.5 m showed that the maximum difference between the two bending lines remains within acceptable limits, confirming the validity of the simplified model for trim calculations. The power‑measurement unit successfully captured shaft speed and torque, enabling a direct link between trim and propulsion power demand.

A significant outcome of the project was the development of the Remote Connection Box, a modular interface that allows remote diagnostics and firmware updates. This tool reduced the need for on‑board service visits, which was particularly valuable during the COVID‑19 pandemic when crew access was limited. The Remote Connection Box has already been deployed in routine service operations outside the project scope, proving its practical utility.

Although the full automated ballast system could not be realised during the project due to limited ballast operations and resource constraints, the work produced detailed functional specifications and a robust sensor architecture that can be built upon in future development phases. The risk assessment performed for sensor failures identified potential weak points and led to the design of mitigation strategies that avoid the need for redundant hardware, thereby keeping the system lean and cost‑effective.

The project was executed over an approximate 18‑month period, culminating in the report dated 16 October 2023. Funding was provided through an industry‑driven research grant, with Hoppe Marine GmbH acting as the sole partner and project lead. The collaboration involved close coordination with ship operators for on‑board testing, as well as with service providers for the Remote Connection Box deployment. The outcomes of the B ZERO Auto Ballasting project lay a solid foundation for future maritime automation solutions that combine precise trim control with efficient ballast management.