Turnout Systems: Intelligent, Connected, and Future-Proof. Systemic Thinking for Excellence in Rail Infrastructure.

From Component to System Concept

An intelligent turnout system includes, among other things, the switch mechanism, the frog, drive and locking devices, base plates, sleepers, fastening solutions, and monitoring systems. However, the true strength lies in the systematic integration of these components.

Uwe Ossberger, CTO Profit Center Turnout said:

A switch system is only efficient if mechanical components, mechatronic systems, and monitoring solutions are perfectly coordinated.

Individual Solutions for Every Application

Each application area places different demands on the switch system:

• High speed: Highest precision and material strength.
• Heavy goods traffic: Extreme axle loads and environmental influences.
• Urban traffic: Compact designs, short response times, quiet operation.
• Mixed traffic: balance between freight and passenger traffic.

Alfred Pölinger, Vice President Product Management said:

Design, materials, signaling switching devices, and monitoring systems form an overall system that is adapted to the load, speed, and environment.

Digital Monitoring for Predictive Maintenance

An intelligent switch monitors its own condition in real time – through sensors, software and data connection.

Ossberger said:

Monitoring not only provides data, but also significantly improves strategic asset management.

Pölinger said:

The boundaries between mechanical, digital, and service-oriented aspects are becoming increasingly blurred – resulting in phygital (physical + digital) systems that are intelligent, adaptive, and networked.

Lifecycle Economic Efficiency (TCO)

The total cost of ownership includes much more than acquisition costs – namely maintenance, downtime and useful life.

• Digital twins for transparency.
• Longer maintenance intervals.
• Retrofit solutions for existing systems.
• Materials with higher wear resistance.

Christoph Fuchs, Head of Customer Solutions, said:

We think in life cycles – from planning to the final inspection.

Technical Expertise & Service Life

The service life of a switch system is largely determined by two factors: the initial quality of the system and the quality of maintenance throughout its life cycle. The key is to select the right solution for the specific application – and to support it with predictive maintenance.

Fuchs said:

For a long service life, you need the right switch for the intended purpose – and the right maintenance at the right time.

Global Expertise, Local Implementation

Systemic competence is created through materials science, engineering and digitalization – combined with a global project network.

Thanks to decades of experience in the manufacture of rails, switches, signaling and monitoring systems, as well as comprehensive expertise and in-house research and development, voestalpine Railway Systems delivers solutions in which hardware and software converge.

Innovative and Future-Proof

Switch systems must constantly evolve – towards higher load capacity, smart connectivity and sustainable materials.

Current developments:

• CO₂- reduced materials.
• Digital twins.
• Simulations & Laboratory Tests.
• Collaboration with universities and operators.

Beyond pure performance, sustainability and regulatory requirements are playing a growing role. ESG criteria and carbon footprints are increasingly crucial in tenders and infrastructure strategies.

Ossberger said:

Sustainability, digital intelligence, and robustness are the cornerstones of the switch of the future.