Project: Pantograph Conditioning Monitoring System – Thornleigh Site

ART has currently completed and installed one PCMS Unit in conjunction with Sydney Trains on the Main North Upline at Thornleigh.

This System is analysing and sending real time data of the Carbon Thickness of every passing pantograph.  Additionally it can detect and recognize irregularities of the overhead wiring arrangements from each passing Train.

This System has been so successful that we have been contracted to install a further 4 Units through the Sydney Network.

Please see Current Innovation section to find our more

Project: IEDR – Internal Emergency Door Release

IEDR_apartDowner EDI Rail (DEDIR) designed an ‘Internal Emergency Door Release’ (IEDR) system for retrofitting to RailCorp’s Millennium and Outer Suburban Cars (OSCAR) rolling stock.

ART succeeded in winning the tender to work in conjunction with DEDIR. We were engaged to manufacture and deliver the IEDR System with a high level of workmanship in a timely manner for the Millennium Train .

Quoted by the Project Manger of DEDIR – ART; thank you for your support with this project, there’s been a few problems to overcome along the way and I think together we’ve done quite well. Sydney Trains are very impressed with the project delivery over the past 6 to 9 months.

Value: $1.2m

Project: HIB – Handset Interface Box

The Handset Interface Box (HIB) was developed to assist United Group Rail in delivering the Digital Train Radio System (DTRS) on board Tangara trains. Working with the customer we designed, manufactured, type tested and delivered over 200 units on time and within budget.

Built to Rolling Stock standards including EN50155 and EN61373, the HIB is the interface between the new digital Funkwerk radio and the Drivers/Guards handset. As well, the HIB assisted in overcoming shortfalls in the operation of the DTRS.

Value: $250,000

Project: ETCS – Electronic Train Control System

Pioneering ETCS in Australia.

The European Trail Control System (ETCS) is the signalling concept that forms the core of automatic train protection (ATP).  This complex system has been developed and successfully deployed in Europe and is now being trialled in Australia.

Australian Rail Technology is pleased to be partnered with Alstom Transport, the front-runner in ETCS technology, to assist their current and future requirements for Sydney Trains to conduct a series of extensive trials on interurban lines in NSW.  ART has been heavily involved with the design, prototyping, and installation of trainbourne equipment.  This equipment has already been fitted on several V-sets, and will soon be trialled on Oscars and Tangaras.  Typical equipment includes:

  • Eurobalise antenna
  • High speed doppler radar
  • wheel speed sensors
  • brake valves
  • GPS antenna
  • data jumpers
  • European Vital Computer
  • driver’s desk display
  • associated framework, enclosures, conduit and wiring

Value $400k

Project: EMU – Brake Control Unit

Innovation in Braking Systems. Contract Manufacture.

The Brake Control Unit is a system used on modern, dynamically braked EMU vehicles, to ensure that air and dynamic braking acts in co-ordination. It interfaces with the train master controller.

An electronic signal from the electric (dynamic) brake, indicating the brake effort achieved, is compared with the brake effort demanded by the driver or an automatic control system. It will then call up additional braking from the air brake system if required.

A$1.5 million contract

Australian Rail Technology was contracted by Knorr Bremse Australia P/L to supply pre-assembled Brake Control Units (BCU) for:

  • 40 Perth Urban Rail Development (PURD) EMU train sets for WA Goverment Railway in 2004-2005 and 2008-2009
  • 65 Interurban Multiple Unit (IMU) for Queensland Rail trains in 2006-07, 2008-09 and 2009-11

ART supplied locally sourced enclosures, sub-frames, internal wiring, and testing. The underfloor mounted electronics enclosures were supplied at an IP65 rating. Custom in-house test equipment was developed for both projects.

Project: Waratah Power Control Systems – Form Fit Relay Solution

The beginning of a 35 year partnership. Advanced Electronics and Power Control Systems.

Originating from the passenger aerospace industry, form fit relay solutions were first used on rolling stock in France, followed by England and then Australia. It is now a model used around the world.

A$16million contract, 35 year Through Life Support (TLS) Contract

At a value of over $16million, Australian Rail Technology was awarded this contract in Australia in 2008, for a four year term, with 35 years through-life-support. The contract included:

  • Fully documented design
  • Shock and vibration to IEC61373 Cat 1
  • Hi Pot and continuity test
  • Functional test
  • Delivery test
  • Routine test
  • Design certificates

Form Fit Relay Solution design and manufacturing

  • 19” sub racks and variations that use commercial-off-the-shelf design.
  • Relay modules (held by the sub rack) with special function relays (timer and voltage sensors) and standard relays.
  • The sub rack internal wiring allows for the setup of logic, interlocks, parallel/redundant circuits and system interface etc. This means easy logic changes can be confirmed in the workshop before installation.
  •  There are 19 different module types used in 68 positions, reducing spares holding and down time.
  • The fixed module design and flexible wiring allows for concurrent design and manufacturing. Six different variations have been developed.

Over a 1000 sub racks have been provided for the new Waratah trains to date.

Project: Waratah Earth Switch

Award Winning Advanced Safety System. High Current, High Voltage.

The Earth Switch project was conceived in 2008. Australian Rail Technology was approached by Downer EDI Rail to create a new product that had never been fitted to a train in Australia.

Review our award here, on the Sydney Trains website, under the heading “Engineering and Projects Group”.

A$4.5 million, 35 year support contract

At a value of A$4.5 million, we were asked to design, test and manufacture a 1500 VDC 2000 amp earthing system for the new Waratah trains (78 set fleet of A-set trains), 936 units in total (4 earth switches and 8 junction boxes per 8-car set).

The function of the Earth Switch, that is manually operated and locked by maintenance workers, is to provide an added level of protection to ensure that all HV circuits of the train are earthed during works.

The core switch mechanism was based on an existing ART outdoor-type DC isolator, reconfigured to fit within a small frame-mount enclosure.


  • Dual contacts to simultaneously earth the main and auxillary HV circuits
  • Rating of IP65, impact resistant stainless steel enclosure, 45 kg
  • 30 micro-ohm contact resistance
  • Mechanically interlocked access panel
  • Auxillary contacts interface with high speed circuit breaker, panograph and eTIS
  • 35 year design life
  • 5000 page documentation pack

Testing completed and accepted by Sydney Trains:

  • IP65
  • Shock and vibration to IEC61373, Category 1, Class A
  • General performance (cycle testing, environmental testing to -5 to +45 deg C, full current temperature rise, dielectric and insulation)
  • Fault current withstand (full load of upstream breaker 1500 VDC at 40,000 amps for 13 ms)
  • Insulators to AS/NZS3121:2000
  • Resistance to vandalism and graffiti
  • On-train integration testing
  • The contract was signed Jan 2009 and manufacturing was completed May 2011

Project: K2RQ OHW Cantilever Assemblies – Kingsgrove to Revesby Quadruplification

Complete that project faster. Infrastructure.

K2RQ is an alliance between Leighton Contractors Pty Ltd, MVM Rail Pty Ltd and Ansaldo STS Australia Pty Ltd. The project involves the quadruplication of track and OHW located between Kingsgrove and Revesby, NSW.

A$2 million plus contract

Australian Rail Technology has contracted to supply and assemble 391 cantilevers, 38 Twin Tension Regulator Assemblies and a small quantity of clamps and jumpers. Delivery of material is to follow a pre programmed schedule allowing six weeks notification prior to possession, commencing September 2010 with scheduled completion in July 2012.

  • ART is responsible for developing a Quality Plan incorporating testing and checking procedures on Suppliers’ incoming material. We conduct a quality inspection (incorporating external examination) on all incoming material for the project.
  • In particular, we have developed our own Inspection and Test Plan to conform with or exceed the requirements of Sydney Trains Engineering Electrical Standard EP08000013SP and all other applicable Australian Standards.
  • We use the computer program “CCalc” together with the relevant Sydney Trains drawings to generate a bill of materials for a cantilever which is assembled ready for erection on site.
  • Regular production meetings are held between ART and K2RQ to facilitate the project.
  • We configure and pre-assemble cantilevers to ensure exact contact wire positioning for specific masts. The result is that individual cantilevers can be dropped on site and installed immediately saving on valuable track possession time.