Enhancing Rail Efficiency for Sustainable Mobility

Rail transport is already low emission, but efficiency can improve. New trains, higher-capacity rolling stock, and advanced signaling like ERTMS Level 2 boost traffic flow and capacity on busy lines like Paris-Lyon. 

Increasing Efficiency in Railway Traffic

Efficiency in railway traffic extends beyond just the movement of trains. It also encompasses increasing train availability, which necessitates a high level of maintenance. Traditionally, maintenance in the railway sector has been both costly and time-consuming.

However, new maintenance paradigms are emerging, driven by advancements in sensor technology, software, and connectivity. By closely monitoring infrastructure and rolling stock with sensors that send data in near real-time to control systems, time-based maintenance can be replaced by condition-based maintenance.

New maintenance paradigms are emerging, driven by advancements in sensor technology, software, and connectivity, allowing issues to be addressed before they lead to breakdowns.

These sensors provide precise information about the state of the equipment, allowing issues to be addressed before they lead to breakdowns. This approach optimizes maintenance costs while preventing unplanned failures.

Predictive Maintenance  in Railway Systems

This proactive, data-driven approach to maintenance can be further enhanced by making it predictive. The predictive maintenance policy is built on top of the data that comes from the equipment. By utilizing AI and machine learning algorithms, engineers can analyze historical data and develop predictive models. This enables railway operators to forecast potential breakdowns well in advance, identifying when and what issues might occur, and allowing them to take preventive actions to avoid disruptions.

Design and Development Optimizations

In addition to operational and maintenance efficiency , there is a need for design and development optimizations driven by market pressure for shorter development and manufacturing cycles. These optimizations can be achieved in numerous ways. For instance, moving towards more standardized and modular designs can save time and drive down CapEx.

Digital tools are also becoming more and more important, and concepts like digital twins and automated testing can speed up time-consuming tasks. Another cost-reduction strategy is to place parts of development projects in best-cost countries, where total cost of ownership is optimized, while ensuring the required quality of engineering work.

ETCS Deployment in Belgium

Akkodis has assisted in deploying ETCS across the Belgian railway network. ETCS is the signaling and control component of the European Rail Traffic Management System, and to ensure efficient deployment, engineering processes had to be automated. Paper-based processes were converted to digital workflows, to save time, reduce errors and optimize the usage of scarce skilled resources. Automation of the ETCS engineering process (Level 1&2) enabled efficient management of changes in railway infrastructure, facilitated traceability and ensured compliance with safety standards. Additionally , it allowed the railway network manager to maintain control of its rail network data.

Automation of the ETCS engineering process enabled efficient management of changes in railway infrastructure, facilitated traceability, and ensured compliance with safety standards.

To achieve these goals, Akkodis developed a suite of process automation tools to expedite engineering studies. The tool suite could generate all information necessary to deploy ETCS (route tables, installation plans, balise configuration, test cases, etc.) and integrated with various legacy systems.

The output of the automated engineering process (installation plan, hardware configuration, documents for certification, etc.) were automatically generated and therefore could reduce the risk of errors and enhance the quality of signaling data. As part of the automation project, Akkodis launched an R&D initiative to automate the capture of signaling information from drawings using Machine Learning and Image Processing.

Innovative Technologies for Inspecting Carbodies

The Gearbodies research project, financed by the EU, has significantly contributed to developing cost-efficient and durable trains. The project aimed to extend overhaul periods and enhance maintenance processes. This extension is achieved through new materials, with Gearbodies prototyping various metal-elastomer running gear components, low life-cycle cost bearings, advanced lubricant solutions, and innovative materials for races and rollers.

Maintenance processes have been improved by developing modular technology to reduce the inspection time of lightweight carbody shells. This solution includes a precisely moving robotized platform that carries all inspection equipment along the carbody. Akkodis has played a crucial role in Gearbodies by designing and constructing the robotic platform and deploying infrared and ultrasound inspection techniques, enhancing composite Non-Destructive Testing inspection algorithms.

Increasing Railway Engineering Capabilities

Customers in the rail sector are increasingly prioritizing the optimization of new development. There is a strong emphasis on shortening development cycles and minimizing costs and delays.

To address this challenge, Akkodis is transforming its project execution and customer collaboration, while migrating specific workloads to best-cost countries. Typically, customers request that at least 30% of Akkodis’ delivery originate from best cost countries. In order to meet that demand, Akkodis is increasing its railway engineering capabilities in these countries, thereby forming a rail Global Delivery team focused on cross-border collaboration and efficient delivery of projects. 

As an example, in 2022, Akkodis, added a rail engineering office in Morocco, a country in which Akkodis started its operations in 2014. The rail engineering office has grown significantly since and has been audited and officially referenced by supplier quality inspectors from some of Akkodis’ major rail customers.

Furthermore, as far as project execution is concerned, there is a move away from a time and material model towards closer engagement with customers and a more work package-oriented delivery model. The work package model ensures that the supplier commits to producing the requested deliverables within a given timeframe and a given budget. The deliverables are then measured on a number of KPIs, such as OTD (on-time delivery) and FTR (First Time Right).

Automated Test Execution

The Akkodis RAMS Center of Expertise in Spain has developed automated test procedures to verify and validate that products, services or systems meet certain requirements and specifications. Engineers create dedicated software to perform multiple tests simultaneously, which are executed much faster by machines than manually. For example, when installing a new track or building a new station it is necessary to test the interlocking system, which is a safety system that connects fixed on-track equipment with rolling equipment.

Extensive testing is needed to verify that the commands sent by the interlocking are received properly by the rest of the safety system. To facilitate this, virtual test benches have been developed, running thousands of test cases to identify potential errors. In the signaling domain, test automation is also a significant focus. Akkodis engineers are automating the development of installation plans for signaling systems. Additionally, test campaigns are generated and executed automatically, allowing engineers to connect to the test device in the field and run comprehensive tests covering all aspects of the device’s functionality. Reports are then automatically generated and stored for easy access by auditors certifying the installation's usage.

Railway Simulators

For over 10 years, Akkodis has developed train simulators to optimize train driver training, similar to how flight simulators train airline pilots. These simulators combine computers and screens with physical controls identical to those in an actual train driver’s cabin. They are modular and can be deployed on heavy simulation platforms (1:1 scale train cabs) or lightweight, self-training equipment like laptops.Using these simulators reduces training time and costs.

Instead of shadowing a trained driver for a year or more, trainees can use the simulator and train in “real” conditions, as it can reproduce existing tracks. This allows new drivers to transition directly from the simulator to the train with minimal supplementary training. Akkodis tailors its solutions to the needs, budget, and configuration of its clients’ training environments. The full replica cab is an exact representation of a driver’s cabin, with all the buttons and controls of a train, and can be built on a motion platform similar to those used in aviation and aerospace. The less expensive ‘light cab’ is equally effective for training, with touch screens replacing most equipment except the speed controller and essential controls like door openers.

Surrounded by large 80-inch screens in a simulation cabin, trainees are fully immersed in the driving experience. In its lightest version, suitable for self-training, the main control console is reproduced by a touch screen and connected via USB. More than 15 of these simulators are currently in operation worldwide. Since 2016, Akkodis has delivered over 20 driving simulator projects for the railway, aviation, automotive, and naval sectors.