A Polish company has created an innovative product with a global railway giant.

• Smart Turnout Powered by Track Tec & Hitachi Rail is a solution integrating the latest generation of turnouts for high-speed railway lines, equipped with a CMS system, integrated with a modern electro-hydraulic switch drive.
• Such solutions are part of the new PKP PLK strategy, which includes actions to improve the safety and efficiency of rail traffic.
• The turnout is the most critical element of the railway infrastructure – the safety, capacity and availability of the railway depend on its reliability.

"We want to invest in Poland and in Poland because we see enormous potential here, both for the development of our business and for modern railway systems, especially for high-speed rail. We are open to local partnerships to build the railway of the future with Polish companies. Responding to contemporary needs and anticipating future challenges, we are constantly seeking new solutions that will increase the reliability and efficiency of railways worldwide . One such solution could be a product like Smart Turnout Powered by Track Tec & Hitachi Rail," says Paweł Przyżycki, CEO of Hitachi Rail Polska.

The most critical element of railway infrastructure

Turnouts are the most critical element of railway infrastructure – their reliability determines safety, capacity, and rail availability. To ensure the uninterrupted, proper operation of turnouts, continuous, remote, and automated monitoring is essential, replacing periodic inspections by maintenance crews.

For this reason, Track Tec and Hitachi Rail have developed an innovative solution: an integrated turnout system , including a turnout with an advanced CMS system and a universal switch drive that could work with international interlocking systems.

In Poland, this would be done through standardization of interfaces at the national level, in accordance with the PKP PLK Ie-114 instruction, and in foreign markets this would be possible thanks to compatibility with the EULYNX standard.

Possibility of early detection of irregularities and faults

A significant role in the Smart Turnout solution Powered by Track Tec & Hitachi Rail is played by the CMS (Condition Monitoring System), a system for monitoring the technical condition of infrastructure, which offers a wide range of possibilities for continuous monitoring of the operation of devices and vehicles, analysis of data on their operating parameters and creation of predictive models.

This enables early detection of irregularities and faults , and consequently, optimization of maintenance work. CMS significantly contributes to increased safety, efficiency, and equipment lifespan, as well as reduced operating costs.

Moreover, it operates independently of existing railway traffic control systems, further improving rail reliability . This is particularly important in an era of increasing cyberattacks and rapidly changing weather conditions, which pose a significant threat to the integrity of railway systems.

In the Smart Turnout Powered by Track Tec & Hitachi Rail solution, the CMS system consists of four independent but cooperating measurement modules.

The first (M1) is an electrical module that measures and records the electrical parameters (current and voltage) of the drive power supply and their switching time. This allows for the analysis of the switching cycle's correctness and the detection of increasing mechanical resistance. This allows for better prediction of drive and switch availability.

Appropriate preventive measures, undertaken as a result of the M1 module's operation, would increase rail efficiency , for example, by reducing vehicle delays on routes. Importantly, this module operates as an "overlay" system, meaning it requires no interference with existing control or power systems.

Assessment of the dynamic condition of the track and identification of deviations

The second module (M2) is a vibroacoustic module based on accelerometers measuring rail (rail stop) vibrations transmitted by the combined turnout sleeper.

Changes in the vibration spectrum may indicate damage to the surface of rail profiles, the running surface of vehicle wheels or wheel suspension systems, as well as degradation of the ballast and track substructure.

Measurement data enables the assessment of the track's dynamic condition, the identification of deviations from the norm, and the predictive detection of potential damage using artificial intelligence algorithms. The system can be updated and developed through the use of newer algorithms, including those based on machine learning.

The next module (M3) is the switch-to-rail position module, where sensors continuously measure the distance between the switch and rail. This enables the identification of irregularities in the contact between the switch and rail, both in a static state and during train passage, before triggering an alarm in standard railway traffic control systems. This would not only improve rail traffic safety but also its efficiency through more accurate prediction of turnout maintenance needs.

The final module (M4) is the weather module, which uses a weather station and temperature sensors installed on the rail to monitor atmospheric conditions such as debris, humidity, and sunlight. Based on this, it can issue warnings, for example, about icing on rails, the temperature of which is also monitored.

The CMS system architecture was designed with ML/AI algorithms in mind. Synchronized data streams from modules M1-M4 have consistent formats and operational metadata that facilitate machine learning and inference.

Hitachi Rail has annual revenues of over €7 billion and employs approximately 24,000 people in over 50 countries.

The Polish company Track Tec produces pre-stressed concrete railway sleepers and other concrete elements adapted to the requirements of all major European railway systems.