A New Era of Freight Monitoring: Smart Wagon® Tracks What Matters Most

Wireless sensors, GPS monitoring, and the analysis of operational data are gradually entering rail freight transport. The company LEVEL Systems is therefore developing the Smart Wagon® system, which enables monitoring of the technical condition of wagons, their load, mileage, and exact position in real time.

The technology is intended to help operators better plan operations and maintenance while also increasing operational safety. In an interview with RAILTARGET, Michal Hojný, Head of Business Development at LEVEL Systems, explained how the solution works, what benefits it brings to customers and where the company is heading next. You can find the full video interview with English subtitles below the article.

From GPS Monitoring to Smart Wagons

LEVEL Systems originally focused primarily on GPS monitoring of freight wagons. The basic function of the system was to track the position of wagons and their movement within the logistics chain. Over time, however, the technology has been expanded with additional functions and sensors that enable monitoring of the wagon’s technical condition directly during operation.

"We started with GPS monitoring, where we mainly tracked the position of the wagon and some basic parameters. Gradually, we began developing additional sensors that can monitor, for example, bearing temperature, vibrations or wagon load. Today, we are trying to move from simple position tracking to a comprehensive overview of the vehicle’s technical condition," explains Michal Hojný.

According to him, an important factor is that the company develops both its own hardware and software. This allows the solution to be adapted relatively quickly to customer requirements. "Developing our own hardware and software gives us great flexibility. We are able to tailor the device exactly to the customer’s needs and respond to the specifics of individual projects," he adds.

Smart Wagon®: Modular and Wireless

At the core of the company’s offering is the Smart Wagon® system. It is based on wireless sensors communicating via Bluetooth® technology. These sensors collect data from individual parts of the wagon and send it to a communication unit, which then transmits the data to the company’s cloud system.

According to Hojný, a key feature of the solution is its cable-free architecture. "The entire solution is completely wireless. Sensors collect data and send it to a communication unit equipped with GPS and GSM modules, which then transmits the data to our Positrex system. The data is stored there and the customer can further work with it," he says.

The system is also designed to be modular. Customers do not need to purchase all functions at once. "A customer can start with position monitoring and later add bearing temperature monitoring, vibrations, wagon load or brake condition. The system can therefore be gradually expanded according to operational needs," he points out.

Preventing Damage Through Real-Time Monitoring

Sensors within the Smart Wagon® system allow monitoring of a wide range of operational parameters. One of the most important is bearing temperature monitoring, which can detect emerging problems early. If the temperature exceeds a set threshold, the system automatically sends an alert to an application or the operator’s control system.

"This allows the operator to replace only part of the bearing and prevent costly repairs or the withdrawal of the entire wagon," explains Michal Hojný.

The system also includes a load sensor capable of determining how heavily the wagon is loaded with relatively high accuracy. "We can determine the load of the wagon with an accuracy of approximately plus or minus two percent. This allows operators to use capacity more efficiently while avoiding the risk of overloading," he says.

The system also enables monitoring of other parameters such as brake pipe pressure, handbrake status or brake block wear.

Predictive Maintenance and Data Use

Predictive maintenance is a major topic in today’s railway sector. The Smart Wagon® system therefore also monitors mileage and other operational data that can help estimate future component wear. "One of the basic functions of our solution is monitoring precise mileage. The operator then knows when maintenance is actually needed and does not have to rely only on fixed intervals," explains Michal Hojný.

Sensor data is stored in the Positrex cloud system, where customers can view it through a clear interface. A mobile application is also available, allowing real-time alerts. "The customer sees journey history, wagon load, mileage and individual alarms. There is also a mobile application for Android and iOS, where push notifications can be received when the system detects a problem," he describes.

Installation in Minutes

Another advantage of the system is relatively simple installation. Most devices can be installed within minutes without major intervention in the wagon structure. "The GPS unit can be attached to the wagon within seconds using a magnet or rivets. Installing a bearing temperature sensor takes only a few minutes," says Michal Hojný. Installation can also be carried out directly in the field, for example on a siding or storage track.

More complex is the installation of certain sensors, such as load sensors, which are usually installed during wagon production due to the need for precise calibration. LEVEL Systems therefore also cooperates directly with some wagon manufacturers.

Bluetooth® Efficiency and Global Expansion

The company has also focused on the energy efficiency of its devices. Bluetooth® technology used in the system is highly energy-efficient and enables long battery life. "Bluetooth® is very energy-efficient, which allows us to achieve a lifetime of up to ten years. Some competing systems require sensor replacement after just three years," says Michal Hojný.

GPS units are additionally equipped with solar panels, ensuring continuous charging. The system is designed to operate in demanding climatic conditions, from African heat to Scandinavian frost.

LEVEL Systems currently operates in most European countries and is gradually expanding beyond Europe. One of the markets receiving increased attention is Poland. At the same time, the company is preparing projects on other continents. "We have an interesting project in Australia, where we will install our devices with a local partner, and we are also cooperating with a partner in India," says Michal Hojný.

The company also regularly participates in industry conferences and trade fairs. This year it attended the European Rolling Stock Summit in Warsaw and is preparing for InnoTrans in Berlin, one of the most important global events in railway technology.