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Axle counting adds fail-safe control to laser diagnostics
Train DetectionFrance

Axle counting adds fail-safe control to laser diagnostics

Country
France
Partner
MERMEC
Segment
Main & Regional Line
Application
Track Vacancy Detection
Products
FAdC, RSR123
Year
2025
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When MERMEC set out to install a laser-based Wheel Profile Measurement System in close proximity to the Eurotunnel, they faced a critical challenge: how to avoid unintended laser exposure without compromising the system’s ability to inspect up to 200 trains per day. To meet these requirements, MERMEC partnered with Frauscher.

In 2025, MERMEC commissioned the installation of a high-speed, laser-based Wheel Profile Measurement System for trains entering the Eurotunnel. This system  can scan up to 150 axles per train for nearly 200 trains per day, at speeds up to 62 mph (100 km/h). The constrained track layout leaves no room for protective barriers, creating a critical safety risk of unintended laser exposure to passengers and nearby trains.

To address this challenge, MERMEC partnered with Frauscher to utilize the Frauscher Advanced Counter FAdC and Wheel Sensors RSR123. Frauscher developed a fully integrated, fail-safe solution that directly interfaces with MERMEC’s laser system. The system dynamically activates and deactivates laser emissions in real time based on train presence, monitored through two critical track sections. Relay outputs are configured to default to a safe state in the event of power loss or faults, ensuring maximum protection.

Delivered as a pre-configured, tested cubical, the solution simplified deployment and minimized the on-site installation effort. Frauscher provided full support during commissioning and handover, enabling seamless integration. By combining precise axle counting with automated laser control, the project delivered a safety certified and future ready setup that eliminates manual intervention and mitigates the risk of accidental laser exposure. This ensures reliable, high-speed wheel inspections in a busy mainline environment.

Partnering with Frauscher on the prestigious Eurotunnel project highlights the power of combining complementary strengths. By bringing our advanced expertise and innovation capabilities together with Frauscher’s renowned know-how, we created a synergy that enabled us to tackle complex challenges and deliver exceptional results.
Enrico Betterle

MERMEC

Dual-track monitoring

The FAdC monitors both adjacent track sections in parallel, enabling precise control of laser triggering based on real-time train detection.

Fail-safe safety logic

Relay outputs are designed to default to a safe state during outages, preventing unintended laser operation.

Turnkey system integration

Solution was delivered in a pre-configured and fully tested cubical, ready for deployment, with installation support included.

Dynamic control for live environments

The intelligent interface ensures that laser systems only activate when safe to do so, which is crucial in busy mainline applications.

Future-ready platform

The flexible internal logic of the FAdC allows the system to be customized according to the operator´s needs, offering a flexible and reliable solution.

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