The Pilot monitoring system is designed primarily for companies which are involved in track maintenance. The system is installed on track machines – sophisticated equipment with high operational costs.

The Pilot system is a software and hardware system for controlling the performance of a machine in real time, assessing its workability, quality of operation and productivity. The system obtains information from the sensors installed on the machine and transfers it to the central server via communication channels. Analysis of the acquired data allows completing the following tasks:

  • obtaining real information about POL consumption
  • preventing breakdowns due to controlling the condition of aggregates
  • assessing the real productivity of the machine
  • assessing the real quality of the machine operation
  • informing the persons concerned about breakdowns and a need for technical maintenance
  • obtaining access to the information about a machine, a group of machines or the track being serviced from any location in the world

the outcome is:

  • Improvement of the general condition of a group of machines.
  • Lower costs related to maintenance of track.
  • Lower administrative costs.
  • Flexible planning of repairs of track and machines.


Subsystem for acquiring data from sensors installed on machine

Every machine is equipped with sensors in addition to the sensors which are part of the control system of the machine. Depending on the type of the machine, from 20 to 120 sensors are installed in addition, which control practically all subsystems: wheel bearers, the main, interaxial, and axial gears, the engine, the hydraulic system, the oil lubrication system, the fuel system, the electrical system and, the most important thing – major operating mechanisms – the tamping unit, aggregates of the excavation chain, the ballast leveler, etc.

The range of the sensors used is virtually unlimited. The Pilot system is compatible both with analog sensors and all major exchange protocols for digital sensors.


Glass-cockpit subsystem

The performance data of all major aggregates and systems of the machine are displayed on the screen of a computer or a tablet. The information about the condition is instantaneous, easy to grasp, and available both for the operators of the machine and employees at any location in the world.


Data communication in real time

Data from the machine are communicated to the server in real time. The server has information about the current condition of the machine (fuel consumption, condition of the aggregates, productivity, etc.) and history reports by all parameters.


Black box subsystem

All the data from the sensors and data from the surveillance cameras are saved and stored on the computer for one month. The data are also transferred to the central server for processing and storage.


Video monitoring system

It performs three functions: event logging, data calculation for controlling the technological processes and a safety function. Key units and aggregates of a machine are under surveillance.
Video is available in real time and is displayed in the operator’s cabin while individual images can be viewed via remote access in real time.



The system provides three levels of reporting:
For service maintenance department – Report on the condition of the machine systems, detailed charts by parameters, recommendations for parts replacement and repairs.
For finance department – Reports on fuel consumption, POL, number of trips and man days of work.
For administration – reports about the entire fleet of machines, the ratio between the planned and actually completed work, quality and scope of work completed by an individual machine and by all the machines.

It should be noted that the Pilot system is a well-proven system both for railroad and quarry machines (dumpers, excavators, graders, etc.). High reliability of the components makes it possible to use the systems in the heaviest duty service.

What machines can be equipped with the Pilot system?

  • tamping machines
  • ballast-cleaning machines
  • dynamic track stabilizers
  • ballast planners
  • track maintainers
  • rail-welding machines
  • rail-grinding machines
  • rail cars
  • railroad and hybrid cranes
  • heavy and light construction equipment