Shunting concepts for rail sidings

The cost-effective and efficient loading and shunting of packaged and bulk goods, liquids, or gases plays a key role in today’s internal logistics processes. Everything must run reliably and on time, while complying with the latest safety equipment regulations and standards.

Cost-effective shunting processes at rail sidings

However, intelligent logistics processes are required to transport goods and merchandise cost-effectively from point A to point B within a company or to transfer them to the rail system. This includes cost-effective shunting operations at freight yards, ports, and maintenance depots to ensure smooth operations there.

Siding operations also present numerous challenges that we repeatedly encounter and must resolve. These include, for example, the fact that track layouts often contain switches, gradients, and track curves. At the same time, railcars must not only be positioned correctly for loading but also shunted over long distances. Environmental conditions are also frequently very harsh, caused by high dust levels or extreme weather conditions.

Additional challenges at rail sidings

Lack of space: On-site rail sidings are often located in confined areas with limited space for shunting maneuvers. This requires precise shunting procedures to prevent collisions and accidents.

Time pressure: Many facilities operate under significant time pressure to avoid disrupting production or transportation operations. This requires working efficiently and quickly without compromising safety.

Diversity: On-site facilities often use a variety of railcars. This requires flexibility and expertise in planning operations and selecting the appropriate technology.

Concepts and Drive Technologies

Efficient and reliable shunting processes are a key component of modern industrial and logistics sites. This is precisely where our solutions come into play. We offer a wide range of shunting solutions that are individually tailored to our customers’ requirements. These include high-performance shunting vehicles, flexible cable-hauling systems, and versatile rail-road vehicles for combined use on both road and rail.

This portfolio is complemented by various drive technologies that can be specifically selected depending on the application scenario. Whether proven diesel drives, emission-free electric drives, cable-tethered systems, or hybrid solutions—each technology offers specific advantages in terms of performance, availability, sustainability, and infrastructure.

Our goal is to develop the right combination of shunting concept and drive technology for every application. This results in tailor-made solutions that are not only economical but also future-proof.

Rope pull system, shunting vehicle, or rail-road technology

Since the 1950s, stationary, cable-driven shunting systems have been used to move railroad cars and trains. With their compact and robust design, they are built to withstand even the harshest climatic conditions and are frequently used in ATEX zones. We select different systems depending on the specific application.

The small push car or the drive chain are closed cable-pull systems and are permanently positioned along the shunting track. The train is coupled via a stop chain or a ball bar. For through tracks, a shunting system with wheel set push trolleys is recommended so that the track remains clear for traffic when the push rollers are retracted. The push rollers can engage with any axle. This enables flexible, fully automatic operations.

For dead-end tracks, a shunting system with standard-gauge push cars is often used. Here, heavy trains with a total weight of up to 4,000 tons can be moved. As an additional option, the push car can extend laterally so that the track remains clear for through traffic.

Compared to stationary shunting systems, the shunting robot is a solution that does not rely on switches or tracks. It can easily move loads of up to 8,000 tons, and thanks to its low purchase and inspection costs, this solution offers an alternative to large shunting locomotives. A variety of drive technologies are available.

Road-rail vehicles are the ideal solution for light shunting operations. They are battery-powered and therefore operate with zero emissions. Using a radio remote control, you can quickly and easily switch from the tracks to the road. Thanks to their high maneuverability and compact design, road-rail vehicles are the ideal solution for any situation where you need to shunt quickly and efficiently across multiple tracks.

Smart Features in Shunting Technology

Digital solutions open up new possibilities in shunting technology. Smart features enhance transparency, efficiency, and safety in operations—and make shunting processes ready for the future.

Precise positioning of railcars

To position railcars precisely, stationary sensors on the track are used today. Alternatively, an absolute or incremental encoder mounted on an additional slip-free wheel is employed. This serves both to record the current speed and as a position measurement system, for example in railcar synchronization. However, a measuring wheel can also be used for slip detection by comparing the actual and target speeds. If there is a significant difference between the actual and target values, sand is scattered between the wheel and the rail to influence the coefficient of friction.

To detect obstacles or to increase safety, the track can be monitored by radar or laser scanners. Scanners can also be used for distance detection, such as during autonomous coupling.

Customized customer interfaces

Another smart feature is the integration of custom interfaces. This makes it easier to integrate modern shunting systems into customers’ central loading control systems. In addition to travel speed, signals to be exchanged often include travel clearances or restrictions. Signal and video transmission is now possible not only via radio but also via a Wi-Fi connection. In drive technology with cable reels, signal transmission can take place via an integrated optical fiber. This allows for the transmission of many more signals and higher data rates.