LEVEL Systems presented its Smart Wagon® solution at the ERS Summit in Warsaw, demonstrating how traditional freight wagons can become data-driven units. According to Michal Hojný: “Predictive maintenance is key to improving safety, reducing costs, and preventing failures in rail operations.”

From Location Tracking to Condition Monitoring

While location tracking was once the main focus, attention is now shifting toward monitoring the actual technical condition of rail wagons. The aim is similar to modern cars—detecting issues early and preventing failures. Smart Wagon® combines a communication unit with a network of wireless sensors that collect operational data and send it to a cloud platform.

Sensors That Improve Efficiency and Safety

The system monitors key parameters such as load, bearing temperature, brake condition, and cargo environment. Accurate weight measurement helps operators optimize capacity and avoid overloading. It also enhances safety. For example, a handbrake sensor can detect if the brake remains engaged, helping prevent wheel damage and unnecessary maintenance.

Predictive Maintenance in Practice

The main value of Smart Wagon® lies in predictive maintenance. Continuous data collection allows potential issues to be identified before they lead to failures or downtime. The results are fewer unplanned outages, reduced maintenance costs, improved operational safety.The hardware is built for extreme railway conditions and is virtually maintenance-free thanks to solar power.

Data-Driven Fleet Management

All data is integrated into the Positrex platform, giving operators a clear overview of fleet movement and condition. It enables real-time tracking, trip history analysis, maintenance planning, and easy integration with existing systems. By connecting hardware, data, and analytics, operators can better manage fleets, optimize usage, and respond quickly to operational changes.

Want to learn more?

Read the full interview HERE:
https://www.railtarget.eu/interviews-and-events/smart-wagon-level-systems-predictive-maintenance-12035.html