New tough tests for the digital freight trains of the future

The FP5-DACtiVate project is gearing up with new tests. Through advanced derailment tests and the evaluation of the new Mix and Match solution in Germany, important steps are being taken towards the digitised railway of the future. Coupler manufacturers and other key players are now gathering to stress-test the technology under extreme conditions.

A central part of FP5-DACtiVate is the focus on the so-called Mix and Match concept. Instead of testing a whole, complete coupler from a single manufacturer, the coupler is now divided into two parts: the coupler head in the front and the draft gear in the rear. The division takes place at a defined interface called Interface A. The figure below shows the assembly of a digital automatic coupler.

The different parts in the Digital Automatic Coupler: coupler head (1), electrical coupler, (2), vertical support (3), draft gear (4) and support plates (5)

This opens the possibility of combining parts from completely different manufacturers on one and the same coupler. This is beneficial for several reasons:

“For us, as a railway undertaking and operator of freight wagons and locomotives, Interface A is the key to interchangeability of coupler components. This significantly facilitates maintenance processes, stock-keeping and the migration phase from screw couplers to DAC”, says Vera-Valerie Capek-Krautgartner, Rail Cargo Group.

Tough tests put Mix and Match to the test in S-curves

Demanding derailment tests in Görlitz, Germany, investigate potential risks with the new Mix and Match solution when it is subjected to compressive forces of up to 550 kilonewtons (kN) in curves. DAC enhances rail safety and requirements for derailment safety are set high compared to the screw couplers that are being used today.

Derailment tests in action with Mix and Match configurations (Photo: Rail Sweden)

“To bring the Mix and Match solution forward, we must compare the risks of these configurations against standard DAC setups. This is why we need to repeat the derailment tests. With the help of the results, we will define a validation plan needed for implementation”, says Anna Björkman, Project Manager Mix and Match.
More tests await

Immediately after the derailment tests, the next challenge awaits in Görlitz when the running ability tests will be conducted in various curves and on ferry ramps with a 30-degree incline.

Overview of the test site in Görlitz, Germany (Photo: DB Cargo)

About the project and its next steps

FP5-DACtiVate is a complement to the FP5-TRANS4M-R project, where the purpose is to conduct additional tests, including Mix and Match tests, DAC validation tests and tests with locomotives.

The project is ongoing until December 2026 and the goal for the Mix and Match part is to finish with a completed, robust validation plan. Before then, however, several important milestones remain, such as specific installation tests to ensure that the assembly in the field will be smooth, and additional tests in Poland under the leadership of PKP.