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Frauscher Marketing
Jan 08, 2026 | 6 min read
The Eurotunnel rail yard is part of one of Europe’s busiest rail corridors, with over 200 trains passing through each day at speeds of up to 62 mph (100 kph). In such a high volume environment, even minor operational disruptions can have far-reaching effects that negatively impact both passenger and freight services. Within this context, MERMEC, a leader in railway diagnostics, was commissioned to install a high-speed, laser-based wheel profile measurement system capable of inspecting the wheels of passing trains. The challenge was to achieve the required precision under strict safety conditions. The limited space between parallel tracks meant that traditional protective barriers could not be installed to prevent unintended laser exposure to other trains or passengers. This required a solution that would activate the laser only when a train was correctly positioned in the measurement section and deactivate it immediately if an adjacent track was occupied, without disrupting the steady flow of traffic or compromising safety.
To meet these demands, MERMEC partnered with Frauscher to implement a suitable solution. At the core is the Frauscher Advanced Counter FAdC, a SIL 4-certified axle counter renowned for its high degree of reliability, modularity and open interface. The FAdC can be configured to monitor two adjacent tracks at once and send precise activation commands to the laser system, making it an ideal fit for this project.
Working to MERMEC’s specifications, Frauscher developed a custom relay interface that facilitates direct communication with the measurement system’s control unit. This allows for real-time enabling of laser emissions based on axle detection, while automatically preventing activation if trains are present on neighboring lines. The interface logic was fine-tuned to ensure uninterrupted operation in the yard’s demanding environment, with parameters such as relay timeouts, current thresholds, and switching logic carefully optimized for reliability, precision, and durability.
An important aspect of the design was its fail-safe mode. In the event of a power loss or fault, the relays default to an open state, keeping the laser inactive. Restarting the system after such an event requires a manual reset, a safeguard that prevents unintended activation and ensures that operational control is never compromised. This attention to safety-critical detail has been central to the system’s acceptance and successful deployment in a challenging setting.
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MERMEC
The result of this collaboration is a fully integrated, pre-configured solution that was delivered, installed, and commissioned with minimal on-site setup. The system includes Frauscher’s robust Wheel Sensor RSR123 trackside, and interface boards housed in a ready-to-use cubicle. Since commissioning, continuous automated wheel diagnostics have been performed without incident in the Eurotunnel yard, maintaining the highest safety standards even under intense traffic conditions. The operator has achieved a seamless blend of safety and efficiency with wheel measurements now taken automatically and accurately without manual intervention requirements during normal operation. Since the system went live there have been zero safety-related stoppages reported by the operator.
This project demonstrates how MERMEC’s leadership in diagnostic technology, supported by Frauscher’s proven axle counting expertise, can deliver targeted solutions to solve unique infrastructure challenges. By integrating high-speed measurement capabilities with intelligent, fail-safe train detection, the Eurotunnel operator benefits from reliable, real-time wheel condition data. This not only helps to address maintenance issues before they escalate and become costly, but also ensures that trains continue to run safely and punctually through one of Europe’s most strategically important rail links. This level of efficiency contributes to the long-term sustainability and operational resilience of the network.
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