Digital Brake and Bearing Monitoring for Track Machines

Plasser & Theurer has equipped its track maintenance vehicles with digital monitoring solutions from PJ Monitoring GmbH, adding automatic brake testing, comprehensive brake monitoring, and real-time axle bearing temperature monitoring to its Datamatic and tmOS digitalisation platforms.

 

Monitoring requirements in track maintenance operations

Track maintenance machines operate under high mechanical loads in constrained time windows, where availability and safety are critical. Components such as braking systems and axle bearings are exposed to continuous stress during worksite operation, transfer travel, and combined transport in train formations. At the same time, these vehicles must move efficiently between worksites, often without onboard personnel during transfer runs.

 

To address these challenges, Plasser & Theurer has expanded its digital vehicle architecture with PJM monitoring functions that provide real-time condition data and automated safety checks.

 

First deployment on a multi-part track laying machine

Three years ago, the first PJM monitoring system was installed on a multi-part track laying machine: a BDS 2000 E³ ballast management system that can be configured with additional conveyor and hopper units. The prototype application focuses on monitoring braking systems in complex vehicle combinations during transport and operation.

 

According to Plasser & Theurer, the objective is to supply train drivers with accurate real-time information on brake condition and axle bearing status, enabling timely intervention and supporting safer, more efficient operation.

 

Comprehensive brake and axle bearing monitoring

The PJM solution continuously records and evaluates brake-related parameters, including functional status, potential operating errors, overload conditions, wear, and remaining service life estimates. In critical situations, real-time warnings are transmitted directly to the driver.

 

In parallel, axle bearing temperature monitoring provides early detection of abnormal thermal behavior, reducing the risk of bearing failure during both worksite movements and transfer travel.
 

 

Automated brake testing in mixed traffic

An integral element of the system is automatic brake testing, a reference technology in European freight transport. Adapted for track maintenance machines and special vehicles, it supports use in mixed traffic scenarios.

 

This capability is particularly relevant when construction machinery is transported to and from worksites either under its own power or as part of a train formation. During such transfers, no personnel are present onboard, yet brake functionality must still be verified. Automated brake testing ensures compliance with safety requirements while minimizing manual intervention.

 

Power supply and data integration

The monitoring system is supported by a proven axle bearing generator that provides an autonomous power supply during track runs and transfer travel. The generator has been adapted to specific machine conditions in collaboration with Plasser & Theurer’s strategic product development team.

 

PJM monitoring functions currently operate as a functional extension to Plasser & Theurer’s Datamatic and tmOS digital platforms. Future integration of PJM subsystems into the full digitalisation environment is intended to enable more comprehensive data exchange, including status and logistics information between worksites.

 

Joint development of future functionalities

The cooperation between the two Austrian companies will continue with the introduction of additional diagnostic functions. One planned option is the IDDS (Informative Derailment Diagnosis System), developed by PJM together with FS LogistiX for freight transport applications.

 

IDDS is designed to inform the train driver as quickly as possible in the event of a derailment-related anomaly via wireless in-train communication. Selected track maintenance machines will be offered with this functionality as an equipment option.

 

By combining PJM’s monitoring technologies with its own digital platforms, Plasser & Theurer is extending condition-based monitoring and automated safety functions into specialized railway construction vehicles. The approach reflects a broader trend toward real-time diagnostics and predictive maintenance in rail operations, aimed at improving safety margins while maximizing the utilization of highly specialized equipment.

 

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