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Schaeffler Advances Freight Wagon Automation with Integrated Power Technologies
Axlebox generators, ITRS power systems and electromechanical actuators enable autonomous energy, digital monitoring and automated functions across rail freight operations.
www.schaeffler.com
A freight wagon with a Schaeffler axlebox generator and a battery management system from Realtronik. Image: (Schaeffler)
Schaeffler has introduced an integrated hardware platform combining autonomous axlebox power generation with electromechanical linear actuation to automate freight wagon operations. Exhibited at InnoTrans 2026 in Berlin (Hall 21, Booth 430), the system supports cargo handling automation, digital automatic coupling, and remote fleet monitoring across the European rail freight sector.
The axlebox generator from Schaeffler is fully integrated, wear-free, retrofittable, and scalable in terms of performance. (Image: Schaeffler)
Autonomous Energy Harvesting and Power Architecture
Conventional rail freight wagons lack onboard electrical distribution networks, which limits the deployment of automated systems and telematics. The Innovative Technology for Railway Systems (ITRS) platform, co-developed with Slovenian engineering partner Realtronik, addresses this limitation by combining an axlebox generator with a dedicated battery management system.
The generator converts wheelset rotation into electrical power and is dimensioned to fit standardized European freight bogies conforming to Y25 and UIC mechanical envelopes. This compatibility allows installation on newly manufactured rolling stock as well as retrofitting onto existing rolling stock during scheduled wheelset overhauls. The harvested electrical energy is stored within an onboard battery pack managed by Realtronik electronics, maintaining an uninterrupted power rail during track idling or marshalling operations. The resulting power supply supports continuous satellite tracking, dynamic load-sensing nodes, automated pneumatic brake testing sequences, and digital automatic coupler mechanisms.
The axlebox generator from Schaeffler is fully integrated, wear-free, retrofittable, and scalable in terms of performance. (Image: Schaeffler)
Electromechanical Actuation Replacing Fluid Power
To automate physical wagon operations without auxiliary diesel or hydraulic ground equipment, the platform uses electromechanical linear actuators from the Ewellix product family. The implementation features the CAHB-2xE series, the CAHB-2xS series with onboard digital controllers, and the heavy-duty EMA series, which delivers dynamic force ratings ranging from 10 kN to 50 kN.
These actuators operate on a power-on-demand principle, drawing current strictly during mechanical extension or retraction cycles, which eliminates the parasitic idling losses and fluid contamination risks associated with hydraulic lines. The integrated smart controllers deliver continuous telemetry on actuator stroke position, movement velocity, and operating current draw, enabling condition monitoring under wide operating temperature profiles. In the event of an onboard electrical bus fault or emergency shutdown, the actuators incorporate mechanical self-locking geartrains, securing hopper discharge doors, cargo tarpaulins, and maintenance hatches against uncommanded release. Field evaluations of the combined energy and actuator architecture are currently underway in operational rail logistics networks.
With its EWELLIX electromechanical linear actuators series CAHB-2xS (smart variant with integrated controller), Schaeffler is offering a highly efficient alternative to pneumatic or hydraulic systems. (Image: Schaeffler)
Additional Context:
This section details technical specifications and competitive benchmarking not included in the original product announcement
Within the railway rolling stock instrumentation sector, autonomous kinetic energy harvesting competes directly with onboard solar photovoltaic arrays, axle-end slip rings, and rival generator designs developed by SKF and Amsted Rail.
A key engineering metric in freight axlebox energy harvesting is generator architecture and electrical power output. Traditional axlebox generators rely on small permanent magnet synchronous generators mounted directly inside the axle cap, typically outputting between 1 W and 5 W. While 5 W is sufficient for low-power telematics and intermittent GPS transmission, it cannot operate high-force linear actuators or motor-driven couplers.
To overcome this constraint, the high-power direct-drive generator topology within the ITRS configuration scales output beyond 100 W at typical freight haul speeds. This matches the instantaneous current requirements needed to recharge buffer batteries while cycling heavy-duty 50 kN linear actuators (EMA series).
Compared to solar energy solutions, which remain vulnerable to tunnel transits, particulate accumulation, coal dust shading, and severe winter conditions, kinetic axlebox generation provides predictable power delivery correlated directly with locomotive traction. However, axlebox generators induce minor mechanical drag on the wheelset bearing assembly, requiring precision thermal isolation to prevent localized heat transfer into the grease cavities of the cylindrical or tapered roller bearings (TAROL units).
Edited by Natania Lyngdoh, Induportals editor, assisted by AI.
www.schaeffler.com
Schaeffler has introduced an integrated hardware platform combining autonomous axlebox power generation with electromechanical linear actuation to automate freight wagon operations. Exhibited at InnoTrans 2026 in Berlin (Hall 21, Booth 430), the system supports cargo handling automation, digital automatic coupling, and remote fleet monitoring across the European rail freight sector.
The axlebox generator from Schaeffler is fully integrated, wear-free, retrofittable, and scalable in terms of performance. (Image: Schaeffler)
Autonomous Energy Harvesting and Power Architecture
Conventional rail freight wagons lack onboard electrical distribution networks, which limits the deployment of automated systems and telematics. The Innovative Technology for Railway Systems (ITRS) platform, co-developed with Slovenian engineering partner Realtronik, addresses this limitation by combining an axlebox generator with a dedicated battery management system.
The generator converts wheelset rotation into electrical power and is dimensioned to fit standardized European freight bogies conforming to Y25 and UIC mechanical envelopes. This compatibility allows installation on newly manufactured rolling stock as well as retrofitting onto existing rolling stock during scheduled wheelset overhauls. The harvested electrical energy is stored within an onboard battery pack managed by Realtronik electronics, maintaining an uninterrupted power rail during track idling or marshalling operations. The resulting power supply supports continuous satellite tracking, dynamic load-sensing nodes, automated pneumatic brake testing sequences, and digital automatic coupler mechanisms.
The axlebox generator from Schaeffler is fully integrated, wear-free, retrofittable, and scalable in terms of performance. (Image: Schaeffler)
Electromechanical Actuation Replacing Fluid Power
To automate physical wagon operations without auxiliary diesel or hydraulic ground equipment, the platform uses electromechanical linear actuators from the Ewellix product family. The implementation features the CAHB-2xE series, the CAHB-2xS series with onboard digital controllers, and the heavy-duty EMA series, which delivers dynamic force ratings ranging from 10 kN to 50 kN.
These actuators operate on a power-on-demand principle, drawing current strictly during mechanical extension or retraction cycles, which eliminates the parasitic idling losses and fluid contamination risks associated with hydraulic lines. The integrated smart controllers deliver continuous telemetry on actuator stroke position, movement velocity, and operating current draw, enabling condition monitoring under wide operating temperature profiles. In the event of an onboard electrical bus fault or emergency shutdown, the actuators incorporate mechanical self-locking geartrains, securing hopper discharge doors, cargo tarpaulins, and maintenance hatches against uncommanded release. Field evaluations of the combined energy and actuator architecture are currently underway in operational rail logistics networks.
With its EWELLIX electromechanical linear actuators series CAHB-2xS (smart variant with integrated controller), Schaeffler is offering a highly efficient alternative to pneumatic or hydraulic systems. (Image: Schaeffler)
Additional Context:
This section details technical specifications and competitive benchmarking not included in the original product announcement
Within the railway rolling stock instrumentation sector, autonomous kinetic energy harvesting competes directly with onboard solar photovoltaic arrays, axle-end slip rings, and rival generator designs developed by SKF and Amsted Rail.
A key engineering metric in freight axlebox energy harvesting is generator architecture and electrical power output. Traditional axlebox generators rely on small permanent magnet synchronous generators mounted directly inside the axle cap, typically outputting between 1 W and 5 W. While 5 W is sufficient for low-power telematics and intermittent GPS transmission, it cannot operate high-force linear actuators or motor-driven couplers.
To overcome this constraint, the high-power direct-drive generator topology within the ITRS configuration scales output beyond 100 W at typical freight haul speeds. This matches the instantaneous current requirements needed to recharge buffer batteries while cycling heavy-duty 50 kN linear actuators (EMA series).
Compared to solar energy solutions, which remain vulnerable to tunnel transits, particulate accumulation, coal dust shading, and severe winter conditions, kinetic axlebox generation provides predictable power delivery correlated directly with locomotive traction. However, axlebox generators induce minor mechanical drag on the wheelset bearing assembly, requiring precision thermal isolation to prevent localized heat transfer into the grease cavities of the cylindrical or tapered roller bearings (TAROL units).
Edited by Natania Lyngdoh, Induportals editor, assisted by AI.
www.schaeffler.com
