Innovating requires courage

The Netherlands is set to implement a new European standard for train protection and traffic management, known as ERTMS. Automation and robotisation are essential to successfully deliver this large‑scale operation. To this end, Strukton has developed the ERTMS Trackbot and the Reality Model. How did these innovations come about?

We go back to 2019. At that time, ProRail had already been preparing the rollout of ERTMS — the European Rail Traffic Management System — for some time. The planning, however, made the organisation pessimistic. The conclusion was clear: this operation required a different approach. ProRail therefore began searching for innovative ways to deploy ERTMS more quickly. The ASAP ERTMS (Accelerated Approach Programme ERTMS) tender was launched across Europe to find innovation partners.

Strukton Rail followed the ASAP ERTMS tender with great interest. Five categories in which innovation was sought were defined,” recalls Ben van Schijndel, ERTMS‑ETCS Programme Manager. “Two of them were particularly relevant to us: faster installation of objects in and directly around the railway track, and smarter design. We decided to submit a bid and won the tender in both categories.”

A solid foundation

A development team got to work. “Fortunately, we didn’t start from scratch in 2019,” explains Corné van de Kraats, Development Engineer. “There were already basic ideas we could build on. For the development of the ERTMS Trackbot, we could draw on our experience with machines and tools, which had shown us how crucial accurate positioning is. We also already had the technology to control our tamping machines to centimetre accuracy using GPS.” For the Reality Model, the Leonardo measuring train provided a strong starting point. Using Trackscan and LiDAR, the railway infrastructure could be mapped in great detail, resulting in point clouds of both the track and its surroundings. “From those point clouds, we believed we could create a digital model,” Corné explains.

ERTMS Trackbot during tests

Finding the right partners

To move from a basic concept to a fully functional solution, the development team sought collaboration with external specialists to supplement missing knowledge and expertise. “We had a clear vision and knew exactly what the ERTMS Trackbot needed to do,” Ben explains, “but we are not robot builders or machine manufacturers ourselves. That’s why we looked for a strong partner — which we found in AMT.” For the Reality Model, further partnerships were established. Saxion University of Applied Sciences conducted research into LiDAR and object recognition in point clouds, while IT specialist Avineon Tensing was brought in to link object recognition to the digital Reality Model.

Working in sprints

Together with their partners, the team set up a development programme. “We worked in something like sprints,” Corné explains. “This allowed us to make incremental progress.” For the Reality Model, the team initially created a manual 3D model of reality. This was then partially automated, followed by an expansion of the amount of information included. Once that proved successful, the process was fully automated. The automated system was first tested on a small area, after which the mapped area was gradually expanded. Unexpected issues arose at every stage — inherent to this approach, according to Corné. “For example, during testing in a small area we encountered a viaduct for the first time — an object we hadn’t previously mapped. You resolve this together and then move on. Step by step, we built the model until we could recognise and represent all relevant objects. At that point, we were ready to apply it at scale in real‑world conditions.”

“ Initially, we created a proof of concept by combining an existing AMT machine with the satellite navigation system we used for our tamping machine. That allowed us to demonstrate that this was technically feasible.” Corné van der Kraats, Development Engineer at Strukton

The same iterative approach was applied to the ERTMS Trackbot. “After proving feasibility, we were able to actually build the Trackbot, then add the robotic arms and the tools required to install axle counters and balises,” Corné explains. “Even then, challenges remained. Tools that worked perfectly in the workshop sometimes failed during testing at the rail centre or on a project site, forcing us back to the drawing board. You keep solving challenges iteratively until you end up with a machine that performs all tasks reliably.”

Avoiding a catch‑22

Beyond the technical challenges, the development teams faced other obstacles. “Track workers must complete training to prove they are competent to work on the railway,” Corné explains. “But how do you demonstrate the competence of a robot? In other words, how do you prove that an innovation complies with regulations — and how do you deal with regulations that change over time?”

“Einstein once said that we cannot solve problems using the same thinking that created them,” Ben adds. “You want to innovate because the current system is no longer sufficient. Yet the innovations you develop must comply with regulations designed for that current system. This creates a catch‑22 situation that can halt progress. We had to be very conscious of this — and still are.”

First production deployment of ERTMS Trackbot

Courage as a prerequisite

After years of development, testing, refinement and re‑testing, Strukton Rail now has two solutions ready for real‑world application: the ERTMS Trackbot and the Reality Model.

“It’s truly amazing to see where we are now,” Corné says proudly. “We’ve worked on this with a dedicated team for five years. That means celebrating successes together, but also dealing with setbacks. Seeing the idea gradually become reality gave us the energy to keep going.” According to Ben, in addition to enthusiasm and perseverance, the process also required courage from all involved: “You have to dare to believe in new technology and be willing to take responsibility for it. We saw that courage in our client ProRail, in our partners, and within our own organisation. Continued support from management was crucial.”

“ You have to dare to believe in new technology and be willing to stick your neck out.” Ben van Schijndel, ERTMS-ETCS Programme Manager at Strukton

Ready for the future

With these developments, Strukton Rail is laying an important foundation for a future in which people no longer have to perform physically demanding work on the railway — in line with the vision of Tjark de Vries, CEO of Strukton Rail Nederland. “And not just for the Netherlands,” Ben notes. “ERTMS is a Europe‑wide programme. We deliberately developed our concept to be as generic as possible, so it can be applied in multiple markets. Automation and robotisation are the future — and we are ready to demonstrate that with our ERTMS innovations.”

“ Automation and robotisation are the future. We are ready to prove it with our ERTMS innovations.” Ben van Schijndel, ERTMS-ETCS Programme Manager at Strukton