Innovative technologies for a sustainable future

The new high-performance maintenance vehicles with an environmentally friendly hybrid drive system play an important role in the ÖBB rail network’s reliability. In the event of disruptions, they are the first to arrive at the scene, with a maximum speed of 120 km/h, and make sure that the railway line can be reopened for traffic as quickly as possible. This way, the machines make an important contribution to highly available railway tracks.

Four modular machine types were developed on a joint basis in order to meet a variety of requirements. The modular design offers machine operating companies and infrastructure managers several advantages: uniform driving control stations, lower training costs for operating staff, and the ability to replace defective modules quickly to minimize downtime. With the E³ technology developed by Plasser & Theurer, all machine types work and travel with zero emissions and little noise.

A new approach to manufacturing

When developing the new vehicles, a reduction in assembly variety was a priority, as was a modular design. In turn, this improves machine commissioning, authorization, and availability.

Already during manufacturing, assemblies are put together as modules for commissioning and tested extensively on specially developed test rigs. Each module has a report with the results; it contains important information for subsequently putting the machine into operation or for overhauls and servicing.

The new manufacturing approach makes it possible to put compact modules together into a complete machine during final assembly, and it speeds up commissioning. This is a major breakthrough for a special-machine manufacturer.

Test phase and positive feedback

The first machines were presented at the beginning of June 2023 at an event with ÖBB-Infrastruktur AG on Plasser & Theurer’s factory premises in Linz. There is currently one machine of each type operating on ÖBB’s rail network undergoing all necessary tests for authorization. All of the machines were developed in conformity with LOC&PAS TSI to ensure trans-European interoperability. They feature the ETCS train control system Level 2 and are authorized according to the Fourth Railway Package.

The feedback from the test runs has been highly positive. The machine staff appreciate the high-quality workmanship and numerous innovative features. What is particularly fascinating is the newly developed drive technology: it makes it possible to switch between various energy sources such as the overhead contact line, battery, or a diesel-electric power pack without interruptions. No comparable machine features this sort of combination with three energy sources.

Its running stability at 120 km/h is impressive, as is the battery’s large range. Regenerative braking is even possible in diesel mode thanks to the wear-free electric braking system. The energy recuperated is mostly used to charge the traction battery, increasing its range. Tandem operation with multiple heading was also mentioned positively. Several machines can be coupled, with the propulsion system of two machines being used and controlled together by a single driving control station. All relevant information, including that of the second machine providing propulsion, is available on an additional monitor.

Tests were performed in a climatic wind tunnel to ensure the operational safety and functionality of the components installed, even under the toughest weather conditions. To that end, the machine operating company developed a testing scenario which is stricter than applicable standards. Specifically, system functionality and performance in diesel and battery mode were proved at temperatures of -25 °C with blizzard and icy conditions as well as up to +45 °C with solar radiation and wind speeds of 80 km/h. A few years ago, the highest temperatures were usually +35 °C. The testing temperature has steadily increased owing to climate change.

The railway as the future’s number one form of transport

The new maintenance fleet is an important step in the future of the railway as a form of transport. ÖBB is preparing for the challenges of our time, particularly with regard to the climate crisis and the necessity of shifting freight and passenger transport to rail. Its stated aims are to double output and to establish a carbon-neutral mobility sector, which are to be achieved by 2040. Plasser & Theurer’s machines are technologically state of the art, providing ÖBB with the best possible support in achieving these ambitious aims.