The twin pillars of safety and operational efficiency have long been of vital importance to the rail operations industry. However, historically, maintenance was generally more of a reactive exercise. It relied on scheduled inspections or responding to failures, often leading to unplanned downtime and unexpected costs.
Thankfully, in recent years the integration of advanced Internet of Things (IoT) technology is changing the way the industry deals with maintenance. This paradigm shift means that adopting IoT telematics is no longer a luxury but a necessity that delivers real-time visibility and a significant reduction in operational risk. This shift is driving the industry from reacting to failures to a more proactive prevention approach. This is having major benefits for both capital assets, as well as the safety of all operatives and the general public.
The digital transformation begins with the locomotives, through the use of sensors that can now collect and transmit data in high detail. This ‘real-time’ flow of information is the basis of all effective IoT telematics.
These systems, such as our LocoWatch here at Clayton Equipment, essentially form a central nervous system for the modern locomotive. The reporting of hundreds of data points in real-time enables proactive fault detection and also reduces the level of risk. This goes far beyond just basic GPS tracking, involving the collection of various performance metrics. This operational data is streamed as it happens so that operators can see exactly what is happening with the locomotive, irrespective of its location.
Performance indicators can include factors such as speed profiles, remaining fuel and, crucially, battery charge levels. With an asset like a train shunter that operates in demanding environments, this level of detail can be transformative. Any changes can be detected quickly, including unexpected voltage drops or overheating – these are issues that could be missed in standard checks. It’s through this stream of data that IoT telematics forms a foundation for a predictive maintenance strategy. This protects high-value assets and ensures engines are always running within safe parameters.
While real-time reporting is essential, the additional value of modern IoT fleet telematics can be found in the layer of artificial intelligence and machine learning that can utilise this data. Systems are now able to look forward, transforming raw data into actionable predictions, addressing any issues before they become serious.
Through the use of predictive analytics, operators are alerted to early signs of failure. These can include changes in wheel bearing wear, motor resistance or the acceleration of battery degradation, and often occur weeks or months before a critical failure. This gives you crucial time to both plan and schedule corrective maintenance. This means that components like brake pads are replaced not based on time schedules but through a data-driven strategy. The industry is now moving away from time-based models toward a more efficient condition-based operation. This could deliver substantial financial benefits, more effectively monitor safety-critical systems and support regulatory compliance.
The financial incentive is also clear. Reducing unplanned downtime through early warning significantly brings down emergency repair costs and extends the useful life of the locomotive.
One of the most significant advantages offered by IOT telematics is the ability to diagnose and often resolve issues without a team needing to physically access the locomotive. This improves response times and minimises disruption.
Using the more advanced IOT remote troubleshooting software, engineers can now analyse data instantly and remotely. They can manually run diagnostics, access the full historical and current operational log from a central control room, all without having to travel to the locomotive location. This allows potential safety issues to be resolved more easily, honing in on the exact component responsible, cutting the time required between identifying a problem and beginning the repair work. For any issues that do not immediately compromise safety, advice can often be relayed to on-board staff so that journeys can be completed safely before being flagged for a more detailed inspection. This capability is vital where network speed and utilisation are constantly under pressure.
The integration of IOT remote troubleshooting software means that, for example, if abnormal wheel temperature is detected, the engineering team can immediately start planning the solution rather than wasting time on diagnostics. This rapid response is critical for both safety compliance and for optimising logistics, ensuring rolling stock remains on the track and not in the repair yard.
The transition to IoT telematics has been proven through successful, large-scale trials across global rail networks, validating the technology’s ability to significantly improve service and safety performance.
Trials have successfully integrated sensor-led IoT telematics, allowing for real-time brake and wheel monitoring, leading to a reduction in incidents as well as improved service safety and reliability. This is providing the kind of evidence needed for regulatory bodies to endorse these modern maintenance practices. Through the use of data-driven monitoring in place of more traditional methods, operators can strengthen safety cases and simplify compliance reporting.
Using the data collected by IOT telematics, operators can provide proof of compliance, with every data point logged to demonstrate speed adherence, engine performance under load and the performance of safety-critical braking systems.
By proactively preventing unplanned downtime, not only are repair costs reduced and vehicle life extended, but the robust data trail provides an essential audit log that satisfies both internal safety goals and external regulatory demands. And all of this provides a solid foundation for establishing a strong overall return on investment (ROI).
IoT telematics is redefining the relationship between the operator, the asset and the network, becoming the crucial step towards achieving a fully interconnected and accident-free railway system.
Proactively manage your fleet's health using LocoWatch™. Contact Clayton Equipment today for more information. Our team is on hand to talk you through the benefits of making the switch to IoT telematics, and can help you to start the process.