Plasser & Theurer is equipping its track maintenance machines with additional digital functions from PJM
posted on 21st Dec 2025 14:24
Plasser & Theurer relies on the advantages of PJM‘s monitoring solutions. Key features include automatic brake testing, brake monitoring, and real-time axle bearing temperature monitoring. These digital train functions complement Plasser & Theurer‘s comprehensive Datamatic and tmOS digitalisation solutions. Together, they enhance the safety, efficiency, and availability of the vehicles.
Three years ago, the first multi-part track laying machine was equipped with a PJM monitoring system. It is a BDS 2000 E3 ballast management system into which additional material conveyor and hopper units can be integrated as required. “With this first prototype, Plasser & Theurer is testing an innovative solution for monitoring the braking system when transporting special vehicle combinations. The aim is to provide train drivers with accurate real-time information, enabling them to intervene promptly. This represents a further step towards greater operational safety and efficiency,” says Bernhard Antony, Head of Strategic Product Development at Plasser & Theurer.
Plasser & Theurer was impressed by the unique functions of the PJM system for real-time monitoring of axle bearings and brake components, as these add value by increasing safety and operational efficiency. Track maintenance machines and their components, such as brakes, are subject to high levels of stress in the challenging everyday environment of railway operations.
However, the vehicles must be highly available due to the limited time available for use on tracks. This system facilitates the exchange of status and logistics information between worksites, enabling a swift transition to the next site. The proven axle bearing generator provides a high-level, autonomous power supply during track runs or transfer travel; it has been adapted to specific machine conditions in collaboration with Strategic Product Development at Plasser & Theurer.
The PJM system is a functional addition to the Datamatic and tmOS systems from Plasser & Theurer. Integrating the PJM subsystems into Plasser & Theurer’s full-scale digitalisation solution in the future will complete the comprehensive package, enabling railway construction companies to make greater use of such subsystems.
Comprehensive brake monitoring
Brake monitoring detects a wide range of data, including information on brake functionality, potential operating errors, defective or overloaded brakes, wear and tear, and the remaining functional life estimate. In critical situations, a real-time warning is sent to the train driver. Another feature of the digital monitoring system is axle bearing temperature monitoring.
Automated brake testing for combined transport
The vehicles are also equipped with an automatic brake testing system, which is the reference system in European freight transport. This system is compatible with track maintenance machines and special vehicles, making it ideal for use in mixed traffic. This system is also relevant for construction machinery, as these machinescan be transported to their place of use either under own power or in a train formation. During transport and transfer travel in a train formation, there is no personnel on board to supervise. Nevertheless, the brakes must be checked.
All other monitoring functions complement the brake test. The two Austrian companies will continue to work together. The IDDS derailment diagnosis function will be offered on selected track maintenance machines. The IDDS (Informative Derailment Diagnosis System) was developed by PJ Monitoring in close collaboration with FS LogistiX (formerly Mercitalia Intermodal) for use in freight transport. This application informs the train driver as quickly as possible via wireless in-train communication.
