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voestalpine Railway Systems

This pilot project, featuring two turnouts equipped with advanced sensor technology, demonstrates how critical rail infrastructure can be optimized for reliability and efficiency in demanding freight operations. 

Project Overview:

The trial involved the installation of zentrak Intelligent Turnouts at two distinct locations: 

  • Location 1: A new #20 RBM turnout provided by voestalpine Railway Systems Nortrak Ltd., installed on wooden sleepers with a rail profile of 136RE. 
  • Location 2: A pre-existing turnout showing significant wear in critical components, including the crossing nose and wing rails. 

Both setups integrated a comprehensive suite of sensors connected to control cabinets for seamless data acquisition.

 

Innovative sensor technology

Sleeper Displacement Sensors

The pilot project featured turnouts equipped with advanced sensors that deliver real-time data to enable predictive maintenance. These included: 

  • Sleeper Displacement Sensors: Monitoring track quality, ballast condition and component temperature. 
  • Acoustic Emission Sensors: Focused on the crossing area to assess wear and component temperature. 

These sensors power multiple diagnostic and prognostic modules, enabling condition-based monitoring and data-driven maintenance decisions. 

Implemented modules & customer benefits

The intelligent turnouts leverage three key modules to maximize operational efficiency and reliability: 

Track Quality Monitoring 

  • Diagnoses track degradation, predicting critical states to optimize maintenance timing (e.g. tamping). 
  • Enhances durability of mechanical parts by monitoring dynamic forces, preventing accelerated wear. 

Crossing Area Monitoring 

  • Assesses wear and predicts the remaining service life of critical components, such as crossing nose and guard rails. 
  • Enables targeted, condition-based maintenance, reducing disruptions and extending component longevity. 

Component Temperature Measurement 

  • Utilizes temperature sensors and weather data to enhance maintenance planning and operational efficiency. 
  • Supports predictive maintenance by identifying temperature-related risks. 
zentrak for heavy haul operations
zentrak for heavy haul operations
zentrak for heavy haul operations
zentrak for heavy haul operations

Your advantages at one glance

The pilot project highlights the potential of zentrak Intelligent Turnouts to transform heavy haul operations: 

  • Seamless integration: The integration with zentrak Asset and Maintenance Management ensures a complete overview of asset data, enabling predictive maintenance to reduce downtime and traffic disruptions. 
  • Enhanced reliability: Early detection of wear and degradation prevents unexpected failures, ensuring dependable operations. 
  • Cost efficiency: Data-driven strategies optimize maintenance, reducing long-term operational costs. 

By implementing these solutions in the pilot, the rail operator reinforces its commitment to operational excellence and showcases the potential of innovative rail technology in heavy haul logistics. 

Explore our solutions

Learn more about how voestalpine Railway Systems is driving the future of intelligent infrastructure solutions for heavy haul operations worldwide. Together, we’re making railways safer, more reliable and cost-efficient.

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