Schaeffler Introduces Axlebox Generator and Linear Actuation Platform

Schaeffler has introduced a suite of modular rail technologies designed to advance the digitalization, connectivity, and automation of freight wagons. The platform integrates wear-free axlebox generators, the modular Innovative Technology for Railway Systems (ITRS) onboard power architecture, and industrial electromechanical linear actuators. The hardware enables freight operators to replace manual trackside interventions with automated wagon handling functions.

Autonomous Energy Harvesting and Power Architecture
Central to the platform is an axlebox generator engineered to supply autonomous electric power at the wagon level, eliminating dependence on locomotive-fed power lines or disposable battery packs. Converting kinetic rotational energy from the wheelset into electricity, the generator provides a baseline power supply for continuous GPS tracking, telematics gateways, cargo load-status monitoring, automated pneumatic brake testing sequences, and powered cargo access doors.

Engineered to fit standardized European bogie architectures, the generator is mechanically compatible with UIC and Y25 axlebox housings. This form factor allows adoption across newly manufactured rolling stock as well as retrofit integration during standard bogie overhaul cycles.

Collaborating with Slovenian technology partner Realtronik, Schaeffler co-developed the ITRS energy platform. The architecture pairs the axlebox generator with a coordinated battery management system to buffer harvested energy, delivering consistent onboard voltage to maintain electronic operations when railcars are stationary. Initial pilot deployments in revenue service have demonstrated field reliability across commercial freight routes.

Electromechanical Linear Actuation and Fail-Safe Mechanics
To eliminate pneumatic lines and hydraulic fluid loops, the platform incorporates Ewellix electromechanical linear actuators. The lineup features the CAHB-2xE series, the intelligent CAHB-2xS series with integrated digital controllers, and the high-force EMA series delivering actuation ratings from 10 kN to 50 kN.

Operating on a power-on-demand cycle, the actuators draw current strictly when actively repositioning loads, mitigating auxiliary power draw. Integrated electronics support real-time digital monitoring of stroke position and actuation speeds while resisting extreme operational temperature variations. To preserve structural safety during transit or uncommanded power interruptions, the actuators integrate internal mechanical self-locking geartrains, securing hopper discharge hatches, sliding doors, and protective cargo tarpaulins against inadvertent release.

Additional Context
This section details technical specifications not included in the original news release.

Axlebox generators function as permanent-magnet synchronous generators (PMSGs) built into the axle journal cap. The permanent-magnet rotor bolts directly to the front face of the wheelset shaft, rotating synchronously with the axle, while the multi-phase stationary stator winding is mounted inside the axlebox housing cover. To accommodate wide operational velocity envelopes, the electromagnetic design incorporates passive or active bridge rectifiers coupled to step-down DC-DC buck converters, generating stable direct-current power outputs ranging from 1 W to 50 W in low-power telematics models and exceeding 100 W in high-power automation configurations at freight speeds between 30 km/h and 120 km/h. Buffer battery modules commonly utilize lithium iron phosphate (LiFePO4) or lithium titanate oxide (LTO) cell chemistries engineered to withstand high vibration profiles up to 5g in compliance with IEC 61373 (Category 1, Class B body-mounted or Category 2 bogie-mounted equipment). These chemistries deliver extended charge-discharge cycle lifespans across operating temperatures from −40°C to +70°C. For heavy-duty hatch actuation, high-load linear actuators utilize hardened ball screws or acme screws driven by brushless DC (BLDC) motors, incorporating Hall-effect pulse counters and absolute rotary encoders to feed stroke positions directly into train communication networks via CANopen or Wireless Sensor Network (WSN) nodes.

Edited by Romila DSilva, Induportals Editor, with AI assistance.