Connect with us

Rail & Road

The Rise of Intelligent Foundries and What It Means for Rail Component Manufacturing

Published

on


Intelligent foundries, also sometimes called smart or Industry 4.0-capable manufacturing plants, are transforming contemporary manufacturing by changing how complex industrial parts are imagined and manufactured.

For railways specifically, for which wheels, bogies, couplers, and propulsion units are required to strictly comply with safety and performance standards, replacing manual, labour-intensive casting and forging with information-led, automated, and integrated foundries is a fundamental shift. On a worldwide level, the foundry service market is set to rise from around USD 65.9 billion in 2024 to USD 111.34 billion by 2033 at a steady 6 per cent per annum. That trend is indicative of an increased adoption level for automation, IoT, and artificial intelligence in industries that call for accuracy, durability, and sustainability. 

A New Era of Rail Manufacturing 

Automation is moving into areas previously considered too complicated to mechanise. Rail component production, which heavily relied on manual inspection and periodic maintenance, often meant extended downtimes, inconsistent quality, and higher operational risk. Intelligent foundries challenge this model by embedding sensors, robotics, and advanced analytics into every stage of production, enabling real-time quality inspection, predictive maintenance, and digital monitoring of key operations. And in freight rail applications, it is dramatically so. Brake testing is a classic example; it used to take several individuals and hours of manual effort. Automated modules perform such checks in minutes, significantly enhancing turnaround while minimizing human exposure to risk. 

Another key frontier is condition monitoring. Globally, wagons already use integrated diagnostic modules tracking axle health, braking effectiveness, balance of load, and even handbrake settings. Sensors take in and report this information in real-time, allowing for predictive interventions ahead of failure. Diagnostic tools like hot-box detectors and wheel-bearing scanning units, once used only on certain routes, are now increasingly standard. Testing demonstrates that advanced machine learning algorithms can overcome temperature-induced sensor distortions, achieving accuracies of around 96.5 percent, and up to 98.2 percent when combined with real-time noise reduction filters, advances that directly enhance reliability and minimize maintenance hazards in rail settings. In India, integration of such smart diagnostics in freight wagons and bogies could prove as transformative as electrification once was, increasing reliability, safety, and asset utilization across the railway network. 

Technologies Driving Intelligent Foundries 

Several technologies converge to make these new systems possible. Automation and robotics enable precise, repeatable tasks possible such as welding, casting, and painting. Robotic arms in foundries can change component geometries with minimal downtime due to advanced software controls. Robotics is increasingly employed for real-time defect inspection, optimization of processes, as well as predictive maintenance. Sensors collect information processed in algorithms involving furnaces, moulds, and machine tools so that the system self-corrects and scrap is minimized. IoT connectivity allows for every key variable, like temperature, vibration, load, or flow of materials, to be continuously monitored and transmitted over secure links for end-to-end transparency in the supply chain.  

Additive manufacturing and 3D printing are also taking hold. For railways, it means possible rapid prototyping and local production near sites of spare parts, such as couplers or brackets, with reduced lead times and reduced wastage of materials. Digital twins, or complete foundry operations in simulation form, allow engineers to test and optimize processes in simulation before putting them into practice for increased efficiency and reduced use of energy. 

Another key opportunity is in integrated data. One casting process creates millions of records, from furnace temperature variations to mould vibration cycles. Gathering it is one thing; seamless movement throughout machines, analysis software, and dashboards is what reveals predictive information, increased productivity, and greater process control. Digital foundries can protect sensitive information while establishing confidence and robustness in their operations with proper cybersecurity.  

Workforce transformation adds another exciting dimension. The foundry workforce has traditionally been hands-on, with deep experiential knowledge of casting behaviour. Intelligent foundries require a hybrid skill set that blends metallurgical expertise with digital literacy. Training programs, therefore, must evolve rapidly to create operators who can manage robotics, interpret AI-driven insights, and still appreciate the nuances of traditional craftsmanship. 

Implications for Quality, Efficiency, and Sustainability 

The advantages of the production of rail components are extensive. In terms of quality, smart foundries utilize computer vision and real-time analysis to identify irregularities during casting or machining. This lowers defects and guarantees conformity with international safety regulations. Nations are importing parts from beyond borders, increasing standardization and ensuring quality more than ever.  

On productivity, predictive analytics and automation eliminate bottlenecks, reducing production cycles by up to 30 percent in some instances. Smart foundries, with their capacity to quickly reorganize production lines and simulate prior to actual casting, enable customization at volume. In rail manufacturers, this translates into quicker turnaround for bogies or wheelsets with reduced defects.  

On sustainability, intelligent energy management systems optimize furnace functioning, conserving energy and emissions. Castings are minimized in defects through AI simulations, saving on scrap and rework. AI-driven casting simulations minimize defects, which in turn reduces scrap and rework. This directly translates into lower carbon footprints across the supply chain, aligning with the global shift toward greener transportation systems. Studies suggest that accelerating the adoption of digital technologies could reduce industrial emissions by 4 to 10 percent by 2030, with the potential to reach 20 percent by 2050 in high-emitting sectors such as energy, materials, and mobility. In rail manufacturing, digitised foundries are contributing to this trajectory by producing lighter, high-strength castings that improve fuel efficiency while lowering lifecycle emissions. 

Opportunities for Innovation 

Apart from prevailing practices, smart foundries are ripe for innovation. Human-robot collaboration (cobots) might enable robots to perform perilous casting tasks while humans monitor them for enhanced safety as well as productivity. Edge AI offers faster, localized defect detection without relying on cloud connectivity, making real-time corrections possible in challenging environments. Green automation, like AI-based scrap car recycling and selective temperature control for specific furnaces, might lower emissions considerably while minimizing costs. All these are ripe for research and development in India, which can make it a leader in the evolution of smart foundry technology.  

India set itself ambitious industrial targets under programs like Make in India and its long-term Viksit Bharat 2047 vision. These ambitions depend on investment, careful and gradual adoption of smart technologies, so as not to introduce fresh vulnerabilities by virtue of modernisation. Managed wisely, smart foundries would alter the industrial makeover in India for good as it drives its trains and its larger aspirations for sustainable, globally competitive manufacturing. 

Disclaimer: The views and opinions expressed in this article are solely those of the author and do not necessarily reflect the official policy or position of Machine Maker or its editorial team. The information provided is based on the author’s personal insights and experiences and is intended for informational purposes only.



Source link

Continue Reading
Click to comment

You must be logged in to post a comment Login

Leave a Reply

Rail & Road

Kineco acquires UK rail componentsfirm, its second int’l deal in 10 months | Goa News

Published

on


Panaji: The Goa-based Kineco Group has acquired TRB Lightweight Structures(TRBLS) — a UK supplier of lightweight components to rail majors, including Hitachi and the London Underground — for an undisclosed price.The acquisition will be housed under Kineco Global Rail, the group’s rail interiors business. This is the company’s second international deal after the purchase of Danish railway sanitation systems firm Semvac AS in Dec.“The acquisition of TRB Lightweight Structures is aligned specifically to the long-term strategic roadmap of our rail-focused brand—Kineco Global Rail. TRB’s legacy and deep expertise in lightweight rail interiors make it a perfect strategic fit. Importantly, both TRB and Semvac combined will now be able to ride on the back of Kineco Global Rail’s large engineering and manufacturing infrastructure in Goa, which is entirely dedicated to the rail interiors market,” said Kineco Group MD and chairman, Shekhar Sardessai.TRB, based in Huntingdon, UK, has over 70 years of experience in manufacturing lightweight components for rolling stock manufacturers in Europe and Asia. Under the agreement, the company will continue to operate under its brand name and maintain its UK manufacturing base.Its MD, Paul Colquitt, said the partnership would allow the firm to sharpen its focus on the rail sector while retaining its identity and operations in the UK.Kineco said the acquisition supports its plan to consolidate niche rail interior brands under one umbrella, as it positions itself to scale in global markets.





Source link

Continue Reading

Rail & Road

Government provides £5m funding for 26 innovative rail projects to boost passenger experience

Published

on


Twenty-six cutting-edge projects that aim to improve passenger experience on the railway have launched as part of Innovate UK’s First of a Kind competition. The projects are being supported by a multimillion funding package by the Department for Transport (DfT).

The First of a Kind competition is run in partnership with Innovate UK, working closely with Network Rail and train operators. It offers grant funding for innovative projects to be tested on the railway, to give them a better chance at being bought by train operators, freight companies and Network Rail.

Given the Transport Secretary’s clear direction to “put passengers at the heart of every journey”, this year’s winning projects focus on improving safety at the platforms, passenger safety and reducing incidents of vehicles hitting railway bridges. The DfT said that, with the collaboration of Network Rail and train operators, these innovations would help to “improve rail services and infrastructure where it’s needed most.”

Among the winning projects is IntelliPan Network, which will reduce delays for passengers by using AI to detect faults on overhead lines, eliminating dangerous, service-disrupting dewirements.

Another successful project, SafeRide 5G, will empower passengers to report incidents using their own devices safely and privately via onboard Wi-Fi, boosting response times and removing key barriers to reporting, improving passenger safety.

Twenty-six successful projects will be supported with £5 million in funding from the DfT, which said this boost demonstrated Government’s “commitment to trialling innovative technology to modernise our railway and boost the passenger experience”. It added that the projects would help to deliver better services for passengers, encouraging more people to take the train and supporting growth as part of the Government’s Plan for Change.

Rail Minister Lord Peter Hendy said: “The winners of this competition are taking cutting-edge technology to address some of the biggest challenges facing the rail industry, making a railway that works better for the people and goods using it.

“These innovations are putting safety, reliability and passenger experience first, like IntelliPan Network using AI to detect faults on overhead lines, reducing disruption caused by dangerous dewirements.

“Through this funding, we are building a platform on which innovation can thrive, giving new technologies a chance to succeed and driving economic growth as part of the Plan for Change.”

Previous competition winners are already being used widely across the railways. Amongst them is the Portable Track Geometry Measurement System, which provides immediate track information to engineers to speed up the lifting of speed restrictions or line closures, getting passengers to their destinations quicker.

Mike Biddle, Executive Director for Net Zero at Innovate UK, said: “The innovations receiving support through this competition will contribute to a more accessible, safer, and efficient railway system throughout the UK. The competition highlights the importance of collaboration with industry partners and focuses on delivering high-maturity demonstrations, ensuring seamless integration into the existing railway infrastructure.

“Delivered by Innovate UK, the UK’s innovation agency, on behalf of the Department for Transport, the FOAK rail programme seeks to identify and support outstanding, innovative solutions. Funded organisations will showcase the creativity and impact of their ideas through live demonstrations.”

The twenty-six successful projects have started work on the new technologies, with testing to take place over the coming months.

Download article



Source link

Continue Reading

Rail & Road

From Guesswork to Data-Driven Maintenance: How LRAIL Transforms Rail Inspection | Sponsored

Published

on


The Challenge: Doing More with Less in Rail Maintenance

Rail operators are under increasing pressure to maintain the safety and reliability of their networks while keeping disruptions to a minimum. The challenge is complex: inspection windows are shrinking, qualified inspection staff are becoming harder to find, and maintenance budgets are under constant pressure. Traditional manual inspections, often carried out on foot with handheld tools, depend heavily on the inspector’s experience and judgment. While experienced crews deliver quality results, human factors such as fatigue, poor weather, and reduced visibility inevitably affect outcomes. This is especially true in complex and safety-critical areas such as turnouts, where small measurement inaccuracies can have serious consequences. In many cases, the data collected during manual inspections is incomplete or inconsistent, making it difficult to move from reactive “fix-when-it-breaks” approaches toward proactive, predictive maintenance strategies. The rail sector increasingly needs inspection technologies capable of delivering fast, consistent, and objective measurements—at full track speed—without compromising accuracy.

Introducing LRAIL: AI-Powered Rail Inspection

Pavemetrics’ LRAIL, now part of the Automated Vision Systems product line within Eddyfi Technologies, was developed to address these exact challenges. This AI-powered, laser-based inspection solution captures accurate, repeatable measurements of all major track components at full track speed. The system combines two high-resolution laser-camera 3D triangulation sensors—manufactured in-house—with integrated inertial measurement units (IMUs) and GPS/INS navigation, enabling the creation of precise, geo-referenced inspection records that can be revisited at any time.

LRAIL automatically detects, classifies, and measures issues such as missing fasteners, irregular ballast profiles, tie degradation, and defects in frogs, switches, and other components—while simultaneously measuring full track geometry parameters—delivering a complete inspection in a single run, without the need for multiple systems, separate passes, or extensive manual follow-up.

A New Standard in Track Inspection

LRAIL redefines what’s possible in railway inspection— especially when it comes to turnouts—among the most complex, costly, and safety-critical track components. Traditionally, inspecting a turnout required slowing down or sending crews on foot for manual walk-throughs, which was time-consuming and left room for inconsistency.

➡ Watch how LRAIL inspects turnouts at full track speed

Operating at track speed, LRAIL captures comprehensive, high-quality measurements of turnouts and all other critical components—including ties, ballast, fasteners, frogs, and switches—in a single high-speed pass. Its integrated system, with perfectly synchronized sensors, ensures that every measurement is taken under the same conditions for maximum consistency.

Operators can define their own grading standards and custom rules, which LRAIL applies automatically and consistently across the network. Geo-referenced outputs in formats such as JPEG, CSV, XML, LAS, and SHP integrate seamlessly into asset management and GIS platforms, enabling teams to quickly pinpoint issues, rank them by severity, and allocate resources where they’ll have the greatest impact.

By turning subjective inspections into precise, consistent data, LRAIL empowers railways to target the right work at the right time and cost—optimizing maintenance, maximizing budgets, and keeping networks moving without disruption.

Real-World Impact: From Two Weeks to Two Days

A recent deployment with a US Class 2 railroad shows how LRAIL transforms inspection speed and data reliability.

Before LRAIL, inspecting a section of track—especially turnouts—took up to two weeks using manual walk-throughs. Inspectors relied on spot measurements at selected points, so results varied by inspector and often left gaps in the record. The process was slow, labor-intensive, and limited in scope, making it harder for planners to see the full picture.

With LRAIL on a hi-rail truck, the same section was inspected in just two days. The system produced a complete digital record of every component—captured to a consistent standard in a single high-speed pass. This detail allowed the maintenance team to base plans on objective, comprehensive data rather than incomplete notes.

The result was not only faster inspections, but a shift to data-driven decision-making: priorities became clearer, budgets more precise, and crews better scheduled.

“We were able to capture our entire single main and east main in record time—over 1.2 TB of high-quality data collected. Using traditional hi-rail methods, this would have taken close to two weeks. With LRAIL, we completed it in just 10–12 hours at track speed. The level of insight we gained in such a short time is truly amazing.”

A Proven Path: Smarter, Faster Rail Maintenance

In an industry where every minute of track time matters, LRAIL is proving that high-speed inspection and uncompromising accuracy can go hand in hand. By delivering complete, geo-referenced data in a single pass, it enables railways to move from reactive fixes to proactive, data-driven strategies—maximizing budgets, improving safety, and keeping trains moving. For operators ready to modernize, LRAIL offers more than just a new tool; it’s a new standard for how rail networks can be inspected and maintained in the years ahead.

Discover how your organization can benefit by visiting www.pavemetrics.com



Source link

Continue Reading

Trending

Copyright © 2025 AISTORIZ. For enquiries email at prompt@travelstoriz.com