"We’re Making Wagons Smarter": LEVEL Systems Showcases Data-Driven Freight Future at ERS Summit

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.

At this year’s ERS Summit in Warsaw, LEVEL Systems demonstrated how conventional freight wagons can be transformed into intelligent units capable of collecting, analysing, and using data in real time. The presentation was led by Michal Hojný, Business Development Leader at LEVEL Systems, who focused on the transition from simple monitoring to predictive maintenance and more efficient fleet management.

Hojný noted that the development of the current solution has been a long-term process. The company began more than two decades ago with GPS monitoring of road vehicles and gradually expanded into the rail sector. "We are trying to make wagons a bit smarter and extract more data from these large pieces of steel than is normally the case," he said at the start of the presentation.

From Position Tracking to Full Technical Monitoring

While position tracking was once the primary focus, attention is now shifting towards detailed monitoring of the technical condition of wagons. Michal Hojný compared this evolution to modern passenger cars, which alert drivers to technical issues before they occur. "Just like in passenger cars, where the onboard system warns you about worn brakes or low oil levels, we want to offer something similar for freight wagons," he explained.

The Smart Wagon® solution is based on a combination of a central communication unit and a network of wireless sensors. These components communicate with each other and transmit data to a cloud platform, enabling monitoring not only of position but also of a wide range of operational and technical parameters.

Sensors Monitor Load, Condition, and Safety

A significant part of the presentation focused on the sensors that form the core of the system. These sensors can monitor wagon load, bearing temperature, the condition of braking components, brake system pressure, and conditions within the cargo space. A key feature is the ability to accurately determine the weight of the load. "Thanks to our technology, you can use wagon capacity more efficiently while avoiding overloading," said Michal Hojný, noting that measurement accuracy is within a few percent.

The system also addresses safety aspects. For example, a handbrake sensor can alert the driver if it remains engaged, helping to prevent wheel damage. "This information can be delivered directly to the driver and prevent the formation of flat spots on wheels," he added.

Predictive Maintenance as the Core Benefit

Predictive maintenance was the central theme of the presentation. Continuous data collection allows potential issues to be identified before a failure occurs. "If we see, for example, that temperature is rising, we send a notification. You can then intervene before a failure or costly disruption occurs," Michal Hojný explained. According to him, this approach significantly improves operational safety while reducing maintenance costs by eliminating unplanned downtime and incidents.

Michal Hojný also addressed the technical design of the system, emphasising that all components are built to withstand extreme railway conditions. "The equipment must operate in a range from minus 40 to plus 60 degrees and withstand water, dust, and other environmental factors," he noted. An additional feature is the communication unit mounted on the wagon, powered by solar energy. This makes the system virtually maintenance-free and easy to install without structural modifications.

Data Platform Enables Real-Time Fleet Management

An integral part of the solution is the Positrex cloud platform, which serves as a central interface for all collected data. It connects the hardware installed on wagons with practical applications for operators and fleet managers.

The platform allows real-time tracking of wagon positions, including detailed railway maps that can calculate actual distances travelled and provide journey history. Users gain a precise overview of vehicle movement across networks and countries. "Once logged into the Positrex platform, you can see all wagon statistics as well as notifications, such as temperature or load data," said Michal Hojný.

In addition to monitoring, Positrex offers advanced operational tools, including maintenance planning and records of visited countries. The platform also supports data export and integration with other systems via API, enabling seamless connection with existing corporate solutions.

The platform’s main value lies in transforming individual data points into a comprehensive overview of fleet condition and utilisation. This allows operators to better plan maintenance, optimise wagon deployment, and respond to operational situations in real time. The presentation reflected a broader trend highlighted throughout the ERS Summit: the rail sector is gradually shifting from traditional operations to data-driven management and predictive maintenance.