Smart data-based assets and efficient rail freight operation

Project Information

FR8RAIL III

Grant agreement ID: 881778

DOI

10.3030/881778

Project closed

EC signature date 20 December 2019

Start date 1 September 2019

End date 30 November 2023

Funded under

• SOCIETAL CHALLENGES - Smart, Green And Integrated Transport

Total cost

No data

EU contribution

€ 5 804 575,54

Coordinated by

DEUTSCHE BAHN AG
Germany

Periodic Reporting for period 4 - FR8RAIL III (Smart data-based assets and efficient rail freight operation)

Reporting period: 2023-01-01 to 2023-11-30

Summary of the context and overall objectives of the project

The objective of the FR8RAIL III project was to further develop technologies which are relevant for the rail freight sector to reach the goal in the S2R Master Plan. Within the challenges highlighted for the rail freight sector, FR8RAIL III further focused on improving the freight eco system by addressing various challenges in 6 different fields:
- Condition based maintenance (CBM)
- Real-time Network Management
- Intelligent Video Gate (IVG) Terminals
- Extended Market Wagon (EMW)
- Telematics & Electrification
- Freight Loco of the future

Within all fields good progress was made. CBM use-cases and business opportunities were further analyzed. Structured dashboards for the status of rail freight assets were developed for a selection of these use-cases.
The final demonstrator for Real-time network management was created and presented to the public. For IVGs the requirements were finalized, and an installation report was created. A demonstrator showing the data capturing of the gates was also in the scope of the project. The EMW, one of the key demonstrators, the specifications of the prototype were finalized and an approval concept for exploitation were created.
Field tests were made for the work within Telematics and Electrification showcasing the potential of different technologies. The overall goal of the last field – Freight loco of the future – was the further improvement of the high-power propulsion system of mainline freight locomotive. This was reached with lab tests for future battery technologies.
To summarize, the project Fr8Rail III delivered important Input for innovations like CBM, asset planning, video recognition, telematics solutions or new assets like the EMW, to improve competitiveness of rail freight.

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 achieved good results for the goals from the Multi Annual Work Plan. For the Condition Based Maintenance (CBM) part a comprehensive overview of use cases was developed and dashboards for displaying the results in a standardized way were created. Workers can use these dashboards to get an overview of the status of the locomotive fleet. For the Real-time Network Management the final demonstrator for operational activities has been released. The concept for the Intelligent Video Gates has been finalized and laid a good basis for the work in the Fr8Rail IV project with the processing of images and the data sharing concept. Video Gates are used to detect damage on the wagons on the basis of high-resolution pictures. The final wagon specification for the Extended Market Wagon, as a key outcome from Innovation Program 5 (Technologies for Sustainable & Attractive European Rail Freight), has been developed. In addition, an approval concept for the future exploitation of the work has been created. Within the work for Telematics and Electrification two field tests took place reaching the final milestones. For the exploitation of the results the Fr8Rail III technical report gives a comprehensive overview of the follow-up actions including continuations within the companies (e.g. CBM), consecutive work in Europe´s Rail (e.g. Flagship Project 3 and Flagship Project 5) or the launch of new processes within the companies. In regards of dissemination the project has used a lot of opportunities to disseminate the work, including a presence at the InnoTrans 2022 (wagon prototypes displayed), several videos and publications as well as social media activities and the participation in conferences.

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)

The expected impacts for the Fr8Rail III project were,
• A 10% reduction of maintenance operational expenses
• A Reduction of the total operating costs for the vehicle and infrastructure by up to 30%, by use of the Extended Market Wagon
• An enhanced environmentally friendly performance through high energy efficiency propulsion systems by 10%;
• A 20% punctuality increase for freight trains arrivals/departures to and from yards by use of realtime network management

The Fr8Rail III developments were providing important input to reach these goals. The work of CBM were supporting to reach a reduction of maintenance costs due to automated detection of failures. Based on expert assumptions this decrease can be reached with future exploitation of the use-cases. The concept of the EMW is showcasing how operations and the infrastructure can be used more efficient. The cost per unit can be decreased by 40 to 50% compared with current intermodal trains. With innovative battery technologies as analyzed within the work of the freight loco of the future the energy consumptions can be decreased. The punctuality can be increased within yards due to the network managements system developed within Fr8Rail III.

Social impact:

CBM: Due to continuous surveillance of locomotives and their components, failures and malfunctions may be detected earlier leading to improved safety in train operations. Moreover, improved service quality and more competitive freight rates may contribute to shift freight volumes to freight rail services.

Real-Time Network Management: The role of different organizations and professionals as timetable planners and dispatchers are under development due to digitalization and automation.

IVG: With the IVG the working processes of yards and intermodal terminals are digitalized and automated. By this better working conditions for staff are created, such as less manual work.

EMW: The extended market wagon concept will improve the noise emission level significantly by using optimised running gears with suspension and damping technology.

Telematics & Electrification: Due to the continuous collection of information from the Wagon Monitoring system part of the wagon intelligence, failures of wagon assets may be detected earlier together with CBM leading to improved safety in train operations. Therefore, Wagon Monitoring System benefits are linked to CBM benefits.

Freight Loco of the Future: Thanks to the improved energy efficiency of the traction chain and the higher operational flexibility thanks to traction batteries, WP6 contributes to the shift of freight transport to rail, improving the overall carbon footprint and sustainability of freight transport.

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