Artificial Intelligence Modernizes Railway Systems 

From predictive maintenance on railcars and tracks to timetable management and Smart City integration, AI and machine learning are transforming modern railways.

High-speed trains, electrification, and the integration of artificial intelligence are transforming global rail networks. Two centuries into its evolution, the rail industry is in a period of rapid and transformative change. Incoming technologies include ultra high-speed trains that can run at 250 kilometers per hour, electric and hybrid fueled rail systems, and communication and logistics networks that connect trains, rail operators, passengers, cargo shippers, and surrounding infrastructure to provide greater visibility and operational efficiency. Now artificial intelligence is augmenting these technologies to further change the way railways are maintained and managed. Advanced interconnects are part of the picture.

“Railway is a demanding industry, and the rail networks are not homogeneous. They are really divergent across different countries, different types of terrain, and have different technologies on board,” said Detmar Saalmann, Weidmüller. The company has 50 years of experience in rail, with multiple divisions and a dedicated product range dedicated to rail technologies. “We have a department which is looking deeply into AI technology, and we have created software for automated machine learning. This gives you the ability to generate business or data modules models and create prediction modules to generate better information, which improves performance across the operation. This is taking place in railways as well as in the machinery market. AI will bring value into rail operations as well.”

Weidmuller’s HDC connectors are used in various rail systems.

AI monitors and shapes rail developments

One way AI can improve railways is through its ability to monitor individual trains and infrastructure. “It gives me the chance to get early information about a breakdown, even timing for when it will happen. This means we can give information to the operation center and the maintenance shop and take the train out of service before the problem occurs. This will reduce unplanned downtime,” said Saalmann.

In addition to predictive maintenance on individual units, AI can be used to improve overall rail systems. The global rail industry is extremely diverse, with varying levels of modernization, many types and makers of rail infrastructure and rolling stock, and country-specific component and safety standards. Component suppliers must evaluate each unique customer request to specify or develop products that will meet the needs at hand as well as provide future performance.

As AI becomes integrated into more rail systems, machine learning processes have larger data sets from which to draw upon to make recommendations for future rail improvements as well as current performance factors. “A lot of companies are using this information to improve their development steps,” said Saalmann. “It can identify the weak points all across the system, thanks to AI data analysis here. Every next innovation will take AI information into account.”

Wagon-to-wagon power jumpers from Weidmüller

binder is enhancing its product lines to meet the rigorous requirements of rail environments while serving applications such as Ethernet-based communication infrastructures, camera-based monitoring systems, and passenger infotainment services.

“The rail industry and the transport sector are becoming increasingly digital. We are currently adapting the M12-X-coded connectors for the specific applications in these target markets. Our connectors will be used in backbone communication structures with high data rates as well as in passenger infotainment systems,” explains Dieter Sandula, Product Manager at binder.

Additionally, emerging applications impose even stricter standards. For example, connectors for railway systems must undergo additional shock and vibration tests in accordance with DIN EN 61373. Passing these tests ensures that the connectors remain fully functional, even during short-term stresses like those encountered in shunting or coupling operations.

binder’s M12-X-coded connectors ensure reliable data transmission in line with the Cat6A standard and adhere to the DIN EN 61076-2-109 standard for mechanical durability, vibration resistance, and effective sealing for connectors used in industrial and harsh environments.

Cleaner rail

Hydrogen and electric train technologies are being integrated into more railways as countries take greater steps towards energy efficiency and sustainability. “A general trend in the market is decarbonization and climate-friendly mobility. In the past, everybody was driving in the metropolitan areas. Now they are stuck in traffic. Of course we need to find other solutions, and one is a better public transport system. Transport solutions can also take advantage of smart phones  — I will call this digitalization; we can use apps to access better and smarter mobile options than before.”

Within trains themselves, Saalmann sees opportunities to generate energy via solar cells or recapture energy through regenerative braking technologies. “We’ll also need to be able to store that energy in a battery. This will, of course, be new technology and we are supporting all these trends and developing it together with the railway industry market.”

High-speed, high-power trains (and interconnects)

As trains modernize, their power demands are increasing, putting pressure on the components inside rail technologies and connected infrastructure. This has challenged suppliers to create new products that support the demands of a harsh environment, rugged operating environment that is also becoming a matrix of new technologies.

“50 years ago, Weidmüller’s portfolio more or less reflected the needs of cabinet building and control of train systems. The inverter system, the door system, the air conditioner, the infrastructure on the ground and the components at the track side. From there, we went into the connectors, the field wirings, and connectors became pluggable. We created industrial HDC connectors, or heavy-duty connectors, which are taking over the communication and from there on we develop further, deeper inside high power range — HDC HP High Power connectors — which are now taking over the high current, high voltage motor connection.” said Saalmann.

SNAP-IN HPC connector from Weidmüller

“As you can imagine, high-speed trains mean more power consumption, in addition to air conditioning, comfort, and entertainment systems on board,” he said. “The need of power distribution onboard trains is increasing too, which means more the components involved must handle higher currents and higher temperatures. We are constantly looking at materials that can withstand higher temperatures and develop products that serve these needs.”

Like this article? Check out our other Artificial Intelligence and Innovation articles, our Transportation Market Page, and our 2024 and 2025 Article Archives. 

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