The digital key technology for transport operators and infrastructure managers

Digital Condition Monitoring: OnTrack

Schunk OnTrack Monitoring - Simplifying Rail Operations and Maintenance with Intelligent Digital Solutions. The safety and efficiency of rail infrastructure and vehicles also depends on the condition of overhead lines and pantographs. But too often, data is lacking quality and quantity needed to derive predictive measures that increase safety and reduce downtime. As a renowned development partner for power transmission technologies for rail systems, we use the Schunk OnTrack Monitoring to upgrade our in-house power transmission systems and make them smart. In this way, we manage to reliably collect as much data as possible in order to use it beneficially.

A comparison with other measuring systems

What makes Schunk OnTrack Monitoring special?

OnTrack is a monitoring system for railroads that works continuously during regular operation and is used to detect and solve problems at an early stage. Compared to existing and established solutions for precisely this area of application, the Schunk OnTrack Monitoring solution from the Schunk Group scores with low hardware costs, as it can be easily retrofitted to existing Schunk pantographs. It is recommended to equip between 10 and 20 percent of the fleet with the system in order to benefit from a swarm intelligence effect. 

Schunk OnTrack Monitoring is known as a robust system that does not require any optical parts at all. Unlike the visual inspection of pantograph and overhead contact line, the actual dynamic interaction is measured, resulting in higher process reliability.

Damaged Spots

Defects on the overhead line are caused either by improper maintenance of the overhead line or by defective contact strips on the current collector. These so-called hardspots can worsen over time. With the help of Schunk's OnTrack Monitoring system, defects on the overhead line can be reliably located, quantified and monitored.

Height & Contact

Defects in the overhead line are caused either by improper maintenance of the overhead line or by defective contact strips on the pantograph. These so-called damaged areas can worsen over time. With the help of Schunk's OnTrack system, defects on the overhead contact line can be reliably localized, quantified and monitored.

Overhead Contact Line Geometry

A catenary laid in an optimum zigzag makes even contact with the contact strip across its entire width of use, thus ensuring the longest possible service life. Schunk's OnTrack system monitors the zigzag geometry, also known as stagger, in order to optimize it if necessary and prevent increased wear.


Sliding Strip

As an elementary component of the current collector, a dysfunction or defect in the contact strips is particularly serious. Thanks to OnTrack Monitoring, it is possible to determine regular wear objectively and automatically and thus plan the right time for replacement.



Schunk Transit Systems

Your expert for digital monitoring


As one of the world's leading and internationally renowned partners for power transmission technologies in the transportation sector, Schunk Transit Systems has special expertise with many years of experience. We see ourselves as an innovation-driven company that wants to use smart technologies and machine learning to create more efficient and reliable overhead line as well as pantograph systems.


This is where our OnTrack Monitoring system solution comes into play, allowing existing current transmission systems to be easily retrofitted and thus made smarter and more efficient. Benefit from the numerous features and advantages of OnTrack Monitoring as well as our decades of experience in the specific field of power transmission technologies and rely on the products and system solutions from Schunk. Schunk OnTrack Monitoring can be retrofitted to many existing pantographs from the Schunk Group. In addition, we will be happy to advise you on the technical possibilities with power transmission solutions when tendering for new vehicle fleets. If you are interested in our state-of-the-art solutions, please feel free to contact us. Our competent team will provide you with information on how we can best support you in your planned project. We look forward to your inquiry. 


Benefit from digital condition monitoring of your rail fleet

Effectively reduce costs thanks to Schunk OnTrack Monitoring

Defective overhead lines and pantographs are typical problems that can cost a transportation company dearly. This is exactly where Schunk OnTrack Monitoring comes in and offers great financial savings potential. Not only are the costs of delays reduced, but the data collected also simplifies scheduled maintenance. Continuous monitoring during regular rail operations enables potential sources of damage to be detected at an early stage. With short reaction times, costly pantograph or infrastructure damage can be avoided. If damage does occur, the data determined by OnTrack enables objective root cause analysis and targeted repairs to be carried out quickly. Last but not least, unscheduled maintenance such as the repair of damaged vehicles and overhead lines can also be carried out more easily, more quickly and therefore always more cost-effectively by using the system.

Self-sufficient and universal - the OnTrack Monitoring system from Schunk

The special feature: with the autonomous system, existing pantographs can be retrofitted, always complying with the applicable railroad standards. An autonomous power supply, high resistance to the environmental influences typical for the application, and a low dead weight create a functional and reliable solution.

Infrastructure and sensor technology - the components of the OnTrack solution

OnTrack Monitoring is made up of various components that interact with each other and make the data-driven system solution possible in the first place. The conventional pantograph is supplemented by various sensors positioned in the areas of the rocker and the base frame. They are able to detect possible faults in the overhead line and the pantograph. The base unit, which is attached to the base frame, ensures the power supply and enables data processing and data transmission via WLAN, GSM and LTE in order to carry out in-depth evaluations quickly and efficiently in the cloud-based database. 

Brochure: OnTrack Monitoring
Brochure: OnTrack Monitoring

Less downtime and maintenance costs

Brochure: Schunk Transit Systems
Brochure: Schunk Transit Systems

Pioneering solutions for the rail and bus industry

Brochure: Stay Connected
Brochure: Stay Connected

Pioneering contact strip solutions
for railway operation



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