Voith Advances Digital Automatic Coupling (DAC) with Electrical and Digital Integration

German company Voith continues to innovate in rail transport by integrating electrical and digital components into its Digital Automatic Coupling (DAC) system. It is set to push European railways closer to full automation and seamless communication between trainsets.

The Scharfenberg coupling, a mechanical foundation developed by Voith, was earlier selected as the standard by Europe’s Rail. Voith is now expanding on this base with the CargoFlex project, which focuses on directly merging electrical and digital technologies into the DAC.

Digital Automatic Coupling: Electrical and Digital Components in Focus

Voith Turbo recently highlighted progress on this project in an interview with Andreas Schuhmacher, Vice President of Freight Coupler Engineering, shared via LinkedIn. CargoFlex aims to integrate data transmission into the coupling system itself, representing a major leap forward in rail modernization. This step enables direct, two-way communication across the entire train set, improving monitoring, safety, and operational efficiency.

Continuous Monitoring and DAC Compatibility with ETCS Level 3

A standout feature of the DAC is its ability to enable continuous train tracking and secure digital communication. The system allows bi-directional data exchange between wagons and the locomotive, providing insights into operational conditions. Furthermore, it is fully compatible with ETCS Level 3, the latest European standard for railway signaling.

Voith engineers have overcome key challenges to ensure durability. To minimize wear, the electrical and digital parts activate only after the mechanical coupling is complete. A unique cam mechanism carefully times the activation, preventing unnecessary mechanical stress and significantly extending the system’s lifespan.

A Durable and Intelligent Buffer System

The DAC’s buffer section absorbs impacts generated when train units couple at 12 km/h speeds. The robust mechanical design effectively manages these forces, exceeding 100 G. To protect its digital components, Voith includes a specialized flap that prevents accidental contact in abnormal operating conditions. Together, these features make the DAC both durable and reliable, ready to withstand the demands of modern railway systems. The DAC also enhances operational safety by reducing the need for manual labor. Its automated processes allow for quicker and more efficient train assembly, while two-way communication improves data protection and compliance with modern standards like ETCS.

Voith: Driving Innovation While Adapting to Economic Challenges

Founded in 1867, Voith is a global leader in engineering with expertise spanning hydraulic systems, paper technology, drive systems, and industrial digitization. The company generates over EUR 5.5 billion in annual revenue and employs more than 30,000 people worldwide. Despite its global reach, Voith remains headquartered in Germany, where it continues to lead innovation in multiple industries.

However, current economic pressures, including rising energy costs, inflation, and market shifts, have prompted Voith to optimize its operations. The company has relocated certain production processes abroad to cut costs and plans to reduce staff levels in Germany. These measures aim to maintain competitiveness and ensure long-term sustainability in the face of global economic challenges.

Challenges and Progress: DAC Deployment in European Rail Freight

The deployment of Digital Automatic Coupling (DAC) technology across Europe is not without its challenges, as it faces hurdles related to data handling, production scalability, and certification. As RAILTARGET previously reported, the 2030 implementation deadline approaches, and rail stakeholders are struggling with uncertainties surrounding how data collected via DAC will be stored and shared. Potential solutions, such as cloud-based storage and contractual data-sharing agreements between stakeholders, are still under discussion within Europe’s Rail Joint Undertaking. Additionally, there is no clear roadmap for scaling DAC production, with estimates of required units varying widely. This uncertainty has led to delays in investments and poses questions about manufacturing capacity, particularly as policymakers at both EU and national levels must commit to supporting production expansion.

Another critical area is the certification and authorization process for DAC retrofits, which could slow down implementation if not streamlined. There is a certain need for flexible regulatory frameworks to avoid excessive barriers for freight operators adopting the technology. While DAC deployment is still achievable by 2030, it hinges on political support and adequate funding, with the pre-deployment phase set to begin in 2026. However, disagreements persist among EU member states regarding funding priorities, with some countries advocating for alternative projects like ERTMS to take precedence. Despite these challenges, DAC remains a central focus in modernizing European rail freight, promising enhanced efficiency, safety, and interoperability once these barriers are addressed.

Source: Voith