Safety and automation for the Zugspitze cable car

The new “Zugspitze cable car” was opened in 2017 on Germany's highest peak, the Zugspitze (2,962 m) . The record-breaking aerial tramway climbs 1,945 metres along a length of 4,467 metres. Two gondolas transport up to 580 people per hour to the mountain station and back to the valley. With up to 5,000 passengers per day, safety is top priority!
That’s why the automation system PSS 4000 is used to ensure safe operation. Together with Frey AG Stans, which has been part of the Doppelmayr/Garaventa group since 1 April 2017, Pilz developed a safe automation solution for the Zugspitze cable car, a solution that controls the whole cable car system.

In particular, PSS 4000 ensures safe control and communication between the overall system and the subsystems, such as the drive controller, remote monitoring system or visualisation.
The automation system is programmed and set up using the software PAS4000. Special deactivation concepts are also part of the solution. “Deactivation concepts are measures that continue to guarantee operation if individual subsystems should fail” says Hansruedi Schleiss, Frey AG Stans. The decisive factor for choosing this solution from Pilz was that the automation system PSS 4000 can control both safety and automation functions. This means that differentiation is no longer necessary between these two functions.

Zugspitze cable car
Martin Hurm, Operations Manager Cable Cars and Lifts Zugspitze, Bavarian Zugspitze Railway.

“The cable car is state of the art. We have a brand new cable car; not only did we get massive hardware in terms of cable car technology but also a super controller and user-friendly visualisation. It's a top solution. We are Top of Germany and we need a top solution.”

Martin Hurm, Operations Manager Cable Cars and Lifts Zugspitze, Bavarian Zugspitze Railway.

The benefits of the application at a glance:

  • The control system combines safety and automation functions
  • Implementation of deactivation concepts
  • Simple programming and configuration with the software PAS4000

“Collaboration with Pilz was always very constructive and positive, particularly in the development projects that preceded this project. So we will work on more joint developments and projects in future and hope to continue this positive collaboration with Pilz.”

Hansruedi Schleiss, delegate of the Board of Directors, Frey AG Stans
Hansruedi Schleiss, delegate of the Board of Directors, Frey AG Stans
Logo Bayrische Zugspitzbahn

About the Bavarian Zugspitze Railway

As a modern service company with a total of 27 mountain railways and ski lifts and seven proprietary gastronomic businesses, the Bavarian Zugspitze Railway transports summiteers to almost 3,000 metres. All year round, about 300 staff welcome guests from all over the world, enabling them to experience an exceptional mountain experience. 

Logo Doppelmayr/Garaventa

About Doppelmayr/Garaventa

As quality, technology and market leader in ropeway engineering, the Doppelmayr/Garaventa group operates production plants as well as sales and service centres in over 40 countries worldwide. To date, the company has built over 14,900 cable car systems for customers in 95 nations. Flexibility, expertise and pioneering spirit make the group ideally equipped to meet all the challenges of traditional and new markets.


Our products in the application:


Pilz Automation Ltd
Pilz House, Little Colliers Field
Corby, Northants, NN18 8TJ
United Kingdom

Telephone: +44 1536 460766

Pilz Automation Ltd

Telephone: +44 1536 460766


Telephone: +44 1536 460866

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