Logo Plasser & Theurer

Autonomous machine

On track to autonomous track maintenance

One important approach to tackling the shortage of skilled workers is the ongoing automation of track maintenance, which also helps to ensure consistently high standards of quality.

The focus is on achieving consistently high performance and quality of work, as well as reproducible results – regardless of the operating staff’s level of experience. To that end, digital assistance systems such as Plasser SmartTamping are used. They combine automated positioning of the work units (Plasser TampingAssistant), automated adjustment of tamping parameters (Plasser SmartReporting), and comprehensive digital (tamping) work documentation (Plasser TampingReport). These systems significantly reduce the workload for operating staff and optimize work processes. They also reduce the likelihood of errors and shorten the duration of training.

Plasser TampingAssistant and Plasser TampingControl reduce the workload for operators and support less experienced staff. The combination of these systems represents a decisive step towards single-person operation of tamping machines and, in the long term, towards fully autonomous tamping. Several trials have shown that automated systems achieve tamping results that match or even exceed the quality achieved by experienced operators.

Step by step to automation

The AI-based Plasser TampingAssistant is the central system responsible for the precise positioning of lifting, lining, and tamping units, particularly in complex areas. Using its sensor technology, which comprises 3D laser scanners and cameras, the system detects and classifies over 60 types of object in real time – including sleepers, cables, and point machines. Based on this data and using predefined tamping plans, it generates recommendations for optimized positioning. The operator simply needs to confirm the recommended positions. All other steps are carried out automatically.​

Plasser TampingControl monitors tamping parameters and adjusts them in real time to ensure a high level of track position durability. The system is based on three components:

  1. BallastMonitoring: assesses the condition of the ballast (from new to highly fouled) during the penetration phase by analysing the interaction between the ballast and the tamping unit segments.
  2. ForceAutomation: automatically adjusts the squeezing force based on various local factors. This reduces the need for manual input and optimizes tamping quality.
  3. VoidDetection: monitors ballast filling beneath the sleeper during tamping. Alerts the operator if insufficient filling is detected, enabling an additional tamping cycle to be carried out immediately in order to prevent voids beneath the sleeper and ensure long-lasting tamping quality.

Together, these functions enable the fundamental shift from the manual operation of machines to the monitoring of systems. As a result, staffing requirements decrease significantly and, in the long term, this means that only one person is needed to operate the system.

Local adaptations with a global impact

Plasser & Theurer’s global network of partners plays an important role. Close cooperation with local partners and customers provides comprehensive insights into country-specific regulations, operating conditions, and customer expectations. These findings make it possible to incorporate local requirements directly into product development. This means that digital assistance systems such as the Plasser TampingAssistant and Plasser TampingControl can be tailored specifically to local requirements, rather than being offered as a one-size-fits-all solution for every market. For customers, this means solutions that integrate seamlessly into existing workflows, provide effective support for their staff, and deliver measurable improvements in quality and productivity.

 

Greater performance through smart technologies in North America

North America serves as an example of ongoing global development and testing under real-world operating conditions: as part of the global Plasser SmartTamping research initiative, the specific requirements of heavy-haul railways were evaluated. The Plasser TampingAssistant was adapted to local machine designs and operating conditions. Following a training phase lasting several months, in early 2025 the system was able to autonomously tamp a turnout in a major North American rail freight network for the first time. These types of international practical operations provide valuable insights for further development of the systems on a global scale.

back to top