Activating DAC Development Through Testing and Engineering

Project Information

FP5-DACtiVate

Grant agreement ID: 101195671

DOI

10.3030/101195671

EC signature date 22 April 2025

Start date 1 December 2024

End date 31 December 2026

Funded under

• Climate, Energy and Mobility

Total cost

No data

EU contribution

€ 5 899 666,20

Coordinated by

DEUTSCHE BAHN AG
Germany

Periodic Reporting for period 1 - FP5-DACtiVate (Activating DAC Development Through Testing and Engineering)

Reporting period: 2024-12-01 to 2025-12-31

Summary of the context and overall objectives of the project

The European transport sector must become more sustainable, efficient, and resilient to meet evolving economic, environmental, and societal demands. Rail freight, as a key component of a low-emission mobility system, needs to transition towards more flexible, customer-oriented, and digitally enabled operations. This transformation is aligned with EU policies such as the European Green Deal and the Sustainable and Smart Mobility Strategy, which aim to reduce transport-related greenhouse gas emissions by 90% by 2050 and significantly increase the share of rail freight.

A key enabler of this transition is the Digital Automatic Coupling (DAC), which replaces manual processes with a standardised, automated, and digital solution. DAC enables longer, heavier, and faster trains, improves safety, reduces operational time, and introduces intelligent functionalities such as real-time data exchange and automated train operations. It forms the foundation for a fully digital, interoperable European rail freight system.

Building on previous initiatives such as Shift2Rail, the European DAC Delivery Programme (EDDP), and FP5-TRANS4M-R, the FP5-DACtiVate project brings together 21 partners across the rail freight value chain. Its main objective is to enable the pre-deployment of DAC-equipped freight trains by validating technologies, components, and system integration under real operational conditions, thereby supporting large-scale deployment in Europe.

The project focuses on four key objectives: (i) validation of pre-deployment trains through comprehensive testing (e.g. derailment, crash, and climate tests), (ii) demonstration of interoperability and interchangeability of DAC components, (iii) integration and validation of hybrid couplers for locomotives, and (iv) large-scale validation of Wagon On-Board Units within the overall system architecture.

FP5-DACtiVate’s pathway to impact lies in accelerating the deployment of interoperable, high-TRL DAC solutions and reducing barriers to market uptake. The project will provide key input to authorisation processes and standardisation, enabling harmonised and cross-border deployment.

The expected impacts are substantial. With over 500,000 freight wagons and more than 15,000 locomotives requiring retrofitting, DAC represents a major industrial opportunity. The project will contribute to increased capacity, improved reliability, and reduced life-cycle costs, while supporting a modal shift from road to rail and reducing emissions and congestion.

In addition to technological and economic benefits, FP5-DACtiVate addresses societal aspects by improving working conditions and safety through reduced manual operations. The integration of Social Sciences and Humanities (SSH) ensures that human factors, workforce acceptance, and organisational change are considered, supported by the involvement of sector stakeholders and social partners.

Overall, FP5-DACtiVate will contribute to establishing rail freight as the backbone of a sustainable, efficient, and resilient European transport system, supporting EU climate goals and strengthening the competitiveness of the European rail sector.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The project has achieved substantial progress across its technical work packages, particularly in testing, validation, and system integration of Digital Automatic Coupling technologies.

In WP1, comprehensive test planning has been largely completed, with all relevant specifications consolidated and submitted in Deliverable D1.1. Major validation activities have been successfully carried out, including derailment tests and climate chamber tests, both completed in 2025 with documented results available. These tests provide critical input for assessing the operational suitability and robustness of DAC systems under realistic and extreme conditions. Further validation activities, including an additional derailment test campaign and crash tests, are planned to extend the dataset and support future authorisation processes.

WP2 has focused on enabling interoperability through mix-and-match testing of DAC components from different suppliers. A detailed risk analysis was conducted to identify key technical challenges related to Interface A, forming the basis for a comprehensive test plan. Test specifications for multiple test sites were developed and consolidated in Deliverable D2.1 which is in its finalisation phase. These activities establish a structured framework for demonstrating interchangeability and reducing the risk of non-interoperable solutions.

In WP3, the project has successfully completed the mechanical and electrical integration planning for the installation of DAC components on locomotives. Particular emphasis was placed on the integration of the hybrid coupler, representing a key technical challenge. This integration has been fully designed and documented based on detailed 3D models, providing a solid foundation for the upcoming installation phase. In parallel, planning for subsequent installation phases has been aligned across project partners.

WP5 has advanced the preparation for integrating hybrid DAC systems on legacy locomotives, addressing both mechanical and electrical aspects. A dedicated mechanical adapter has been designed to enable installation with minimal modifications to the locomotive structure and validated through 3D simulations. In addition, static and dynamic analyses have confirmed the feasibility of the integration in terms of structural integrity and operational constraints. Preparatory work on the electrical system, including power supply adaptation and component selection, is ongoing. The collection of technical data required for upcoming functional tests is also well advanced, particularly on the mechanical side.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

Not applicable