Railways are a central component of global trade. As an environmentally friendly, safe and cost-efficient mode of transport, it makes a significant contribution to sustainable logistics. At the same time, the demands on availability, safety and transparency are constantly increasing.

One particular challenge is the early detection of damage to freight cars: traditional visual inspections are time-consuming, labour-intensive and often only possible on a selective basis.

A Project with Added Value for the Industry

To meet these requirements, a cross-divisional project was launched in 2020. voestalpine Signaling Siershahn GmbH, a subsidiary of voestalpine Railway Systems, teamed up with Logistik Service GmbH (LogServ), part of the voestalpine Steel Division, to develop an intelligent solution with real added value for the industry. While voestalpine Signaling Siershahn develops and implements sensor technology and software solutions for the railway industry, LogServ contributes its expertise in the operation of connecting railways, railway transport companies and the maintenance of freight cars.

The common goal: to proactively detect damage to increase safety, reduce downtime, and optimize processes.

The solution – zentrak from voestalpine Railway Systems.

zentrak VISUAL TRAIN ANALYSIS (VTA) – Innovation Directly on the Track

zentrak VTA represents a groundbreaking innovation in the field of camera-based condition analysis of freight cars. It enables precise recording of the condition of vehicles while they are in motion – without stopping – thus significantly optimising maintenance and operating processes. Even at speeds of up to 250km/h.

Five high-resolution industrial cameras, which can be used in either the near-infrared or colour range, and nine flashlights, which operate in the visible or invisible 850nm range, document every passing car from both sides as well as from above. In this way, potential damage or wear and tear on safety-relevant components can be detected at an early stage.

In addition, zentrak VTA supports operations by:

. Automatically recognising UIC car numbers, revision data and QR codes

. Identifying hazardous goods labels

. Checking that tarpaulins are locked correctly

In addition to damage detection, the system also saves time during train dispatch. As a learning system, zentrak VTA is continuously being expanded – for example, with new functions such as colour cameras for extended applications such as scrap sorting, automatic evaluation of the load limit grid, or wheel thickness measurement.

Michael Wollendorfer, Project Manager, LogServ Logistics Engineering, said:

"We see great potential in using the generated data to further optimise our processes and procedures. I am sure that this is only the beginning."

zentrak FLEET CONDITION MONITORING (FCM) – Intelligent Data Analysis

LogServ receives an overview of all relevant data using the zentrak FCM software. The collected data from zentrak VTA and other sensors is transferred to zentrak FCM, where it is evaluated and then displayed in an intuitive dashboard. Users, such as fleet managers, thus receive a comprehensive overview of the condition of their railcars. Image data can be accessed directly via the respective car in the Explorer view, examined and compared with the evaluated measured values.

The ability to compare images of a wagon across different measurements is particularly helpful. For example, it is possible to determine whether damage was already present when the wagon arrived at the depot or whether it occurred during its stay there. Two measurements of a wagon can be easily compared in zentrak FCM. This ensures transparency and traceability.

In addition, other sensors installed in the track continuously collect data from individual railcars, which is evaluated using powerful algorithms. These algorithms not only detect when defined limits are exceeded, but also anomalies within normal ranges that may indicate an impending defect. This is an important step towards predictive maintenance, planning and maximum safety.

Furthermore, zentrak FCM allows a detailed view of individual railcars, including historical measurement trends and an overview of current measurements. Widgets such as ‘Fleet Coverage’ – which indicates vehicles that have not been measured in the field for a long time – further increase the transparency of measurement coverage.

The system thus offers not only a precise condition analysis, but also a powerful tool for optimising processes and increasing availability and safety in rail freight transport.

A Step towards Future Viability

The partnership project between voestalpine Signaling Siershahn and LogServ impressively demonstrates how modern technologies can make rail freight transport safer, more efficient and more sustainable. With zentrak VTA and the zentrak FCM application, it is possible to:

. detect damage at an early stage

. optimise processes

. plan maintenance in advance

This reduces costs and saves time. The combination of camera-based analysis, sensor technology and intelligent data evaluation creates transparency and significantly increases operational safety. This not only increases efficiency but also makes an important contribution to the future viability of rail as a mode of transport.

www.voestalpine.com

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