LEVEL Systems Heads to Congress in Wisła to Present Smart Wagon® Solution

Technology company LEVEL Systems will also take part in the International Railway and Intermodal Congress in Wisła, Poland. The company will present its Smart Wagon® solution, which enables real-time monitoring of the technical condition of freight wagons using wireless sensors.

LEVEL Systems has been engaged in vehicle monitoring for approximately 25 years. Initially, the company focused primarily on GPS tracking of passenger and commercial vehicles, but gradually expanded its activities into the rail sector. In recent years, it has concentrated mainly on freight rail wagons, offering not only location tracking but also detailed monitoring of technical condition and operational parameters.

The core of the solution is a communication unit installed directly on the wagon. This unit collects data from individual sensors and transmits it via the mobile network to a central system. Operators thus gain an overview not only of wagon movements, but also of their technical condition, load status and operational history. The data are available in real time through a software platform that allows users to monitor individual wagons, their operation and their history.

Smart Wagon® Enables Early Fault Detection and Reduces Repair Costs

A key component of the Smart Wagon® system is its wireless sensor technology using Bluetooth® communication. Sensors installed directly on the wagon collect data from critical components and send them to the main monitoring unit, which then transfers the data to the central system. This makes it possible to monitor the technical condition of wagons in real time without the need for physical inspections or cabling installation.

Monitoring bearing temperature plays a particularly important role. Overheating bearings are among the serious technical issues that can lead to bogie damage and the withdrawal of a wagon from service. Early detection allows operators to respond before a more extensive failure occurs, reducing repair costs and operational losses caused by downtime.

Another important function is load monitoring. A specialised sensor can determine the wagon’s load with an accuracy of approximately ±2%. This enables operators to make better use of capacity while avoiding overloading, which could result in equipment damage or financial penalties. The system therefore helps optimise logistics and improve transport efficiency.

Smart Wagon® also tracks mileage and other operational data that are essential for maintenance planning. Operators can set automatic alerts, for example when a certain mileage threshold is reached or when a technical issue occurs. Maintenance can thus be scheduled based on actual wagon usage rather than fixed intervals, contributing to lower costs and higher fleet availability.

Smart Wagon®: Fast Installation and Scalable System Expansion

One of the main advantages of the solution is its simple and rapid installation. The basic monitoring unit can be mounted on a wagon within a very short time, while installing certain sensors (for example, on bearings or the hand brake) takes only a few minutes. Thanks to its wireless architecture, there is no need to install cabling or carry out major structural modifications to the wagon.

The system is designed as modular, allowing for gradual expansion. Operators can start with location tracking only and later add additional sensors according to their needs, for example for monitoring load, vibrations or other technical parameters. A single communication unit can receive data from a larger number of sensors, making it possible to tailor the scope of monitoring to specific requirements.

The collected data are displayed in the Positrex software platform, where operators can monitor wagon movement history, load status and technical condition. The system allows users to set automatic alerts, track operational statistics and integrate the data with the customer’s internal systems, facilitating fleet management and maintenance planning.

LEVEL Systems is already deploying its solution with customers in several European countries and is also cooperating with railway vehicle manufacturers to integrate sensor technology directly into new wagons. The technology is designed to operate across a wide range of climatic conditions and to be compatible with various types of freight wagons.

Smart Wagon® Technology to Be Presented at Conference in Wisła

LEVEL Systems will present its Smart Wagon® solution at the International Railway and Intermodal Congress 2026, which will take place from 4 to 6 March in Wisła, Poland. The conference is one of the key railway industry gatherings in Central Europe and regularly brings together rolling stock manufacturers, operators and technology companies from the Czech Republic, Slovakia and Poland.

Poland is an important market for LEVEL Systems. The company is gradually expanding its activities there and establishing cooperation with partners in both wagon manufacturing and operations. The presentation at the conference aims to introduce the technology to a broader audience and establish new contacts.

The digitalisation of freight rail wagons is gradually becoming a standard in modern rail transport. Solutions such as Smart Wagon® demonstrate how the combination of sensor technology and data analytics can enhance operational safety, reduce maintenance costs and improve fleet utilisation efficiency.