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Artificial intelligence streamlines relay identification for Swiss Federal Railways
Streamlining railway operations with artificial intelligence (AI)
Efficient railway operations depend on the seamless functionality of critical components such as rail relays, the backbone of railroad signaling systems. Rail relays are electromagnetic devices that control the flow of electrical current in the signaling system. Their primary function is to detect the presence of trains, control signal lights, and manage track circuits. They help ensure that trains can operate safely by providing real-time information about the state of the tracks, signals, and switches.
At the Swiss Federal Railways (SBB), these relays play an indispensable role, with 700,000 units in operation. “Managing this enormous inventory has always posed significant challenges, particularly in identifying the wide variety of relay models,” explains Markus Aebi, Head of Manufacturing and Safety Systems at SBB.
Innovative AI solution by CSEM
In response to these challenges, CSEM has developed a custom AI-driven identifier for safety relays, equipped with Deep Learning Character Recognition (Deep OCR) technology. “Working closely with SBB, we have developed a tailored AI rail relay identifier,” states Silvan Widmer, Principal Engineer, CSEM. “This advanced system has fundamentally transformed how relays are identified and cataloged, reducing manual labor and improving operational efficiency.” With a remarkable identification accuracy rate of 97% in a factory acceptance test, the system has revolutionized inventory management for SBB, enabling employees to focus on higher-value tasks.
The burden of manual identification
Historically, identifying relays has always been a time-consuming process. Each year, thousands of relays are returned from SBB’s safety systems to its Railway Technology Center for refurbishment and maintenance. Without a complete digital inventory management system, 900 relay model types had to be visually inspected and cross-referenced against extensive lists. Specialized employees performed this tedious task, often spending up to five minutes identifying a single relay. The process was not only monotonous but also prone to human error, which could disrupt maintenance schedules and delay railway operations.
Overcoming labeling obstacles
One major obstacle was the outdated and inconsistent labeling on many relays. Some labels featured standard numerals, while others used Roman numerals or handwritten markings, reflecting the evolution of manufacturing practices over the decades. Deciphering these diverse formats required meticulous attention to detail and significant time investment from SBB’s employees.
Revolutionizing identification with AI
CSEM’s AI safety relay identifier has revolutionized this process. “By utilizing advanced optical scanning technology, the system can instantly recognize and decode the diverse labeling styles found on SBB’s relays,” highlights CSEM’s team. “The Deep OCR engine powers the identification process, interpreting printed and handwritten characters with remarkable precision.” Once a relay is scanned, its details are processed and presented on CSEM’s VISARD platform, a user-friendly interface that simplifies data interpretation. The entire identification process now takes just 20 seconds per relay, a dramatic improvement over the previous five-minute timeframe.
Significant benefits and efficiency gains
Over the past year, SBB has successfully processed 15,778 relays using this technology. “By automating this labor-intensive task, the AI rail relay identifier has freed skilled employees from repetitive duties, allowing them to focus on critical maintenance and operational tasks,” notes Aebi. This shift not only improves job satisfaction but also enhances overall efficiency within the organization. Furthermore, the integration of a QR code printer ensures that every identified relay is equipped with a unique, scannable label, simplifying future inventory tracking and management.
Transforming inventory management
By addressing the challenges associated with outdated nameplates and manual identification, the AI rail relay identifier has transformed SBB’s inventory management processes. The solution has already saved over 1,000 hours annually and minimizes errors, ensuring consistent and reliable relay tracking. For an organization as complex and safety-focused as SBB, these improvements are invaluable. Beyond its operational benefits, the system demonstrates how artificial intelligence can modernize traditional industries.