Hybrid Coupler Integration – Status Update Work Package 3

Within the framework of the Europe’s Rail Joint Undertaking, the FP5-DACtiVate Work Package 3 is advancing the practical application of interoperable systems developed under FP5-TRANS4M-R. The focus lies on integrating a Digital Automatic Coupler (DAC) and a Consist Control Unit (CCU) into a Stadler EuroDual locomotive, marking a key milestone towards the digitalisation and automation of European rail freight operations.

The work package brings together leading industry stakeholders: Stadler Rail Valencia S.A.U. (STAV) as locomotive manufacturer, Havelländische Eisenbahn AG (HVLE) as the operator and owner, and Knorr-Bremse SfS GmbH (KB) as the technology provider for the DAC and CCU systems. This collaboration ensures both system interoperability and operational relevance.

The installation, commissioning and testing activities are structured into two phases. The first phase was successfully completed at HVLE’s workshop in Berlin-Spandau, located near the FP5-TRANS4M-R Train Test Lab. During this phase, key components including cabling, the traction unit power supply system, CCU devices, junction boxes, draft gear, and the vertical support structure for the hybrid coupler were installed and partially commissioned.

CCU components and wiring harness demonstrating system integration.

Front view of locomotive with installed system interfaces for DAC preparation.

Following this initial setup, the locomotive has temporarily returned to commercial service using a conventional screw coupling, while the CCU components were de-installed for further optimization. This pragmatic approach ensures continued operational availability while preparing for the next development stage.

The second phase, scheduled to commence in August 2026, will focus on re-installation and full functional validation. This includes comprehensive testing of locomotive functions, DAC-based coupling and decoupling operations, train composition detection and automated brake testing. These demonstrations will provide critical validation of system performance under realistic operating conditions.

During InnoTrans 2026, the locomotive will be presented at the Train Test Lab, offering stakeholders and decision-makers the opportunity to experience the technology first-hand. Following the exhibition phase, the work package will conclude with final reporting within the FP5-DACtiVate project.

CCU user interface showcasing digital train functions such as automated brake testing.

The outcomes of this work package represent a significant step towards large-scale deployment of DAC technology in Europe. By validating interoperable and digitalised coupling solutions, the project contributes to enhancing efficiency, safety and competitiveness of rail freight, while supporting the broader objectives of sustainable transport and modal shift.

Title image: Stadler EuroDual locomotive (HVLE 159 004) serving as test platform for DAC integration
Copyright all images: Knorr-Bremse SfS GmbH