Products and systems we have built

Railways

HABD: Hot Axle Box Detection

Overview

HABD is a trackside unit that checks the bearings of every passing train. Two inductive proximity sensors detect each axle, while infrared pyrometers on both sides of the track read the axle-box and wheel-rim temperatures. The unit stores one record per train and uploads it over 4G, so maintenance teams can spot an overheating bearing before it fails.

Key features

• Axle-by-axle temperatures for the left and right axle boxes and wheel rims
• Automatic axle counting, train direction and timing for speed calculation
• Ambient rail temperature recorded with every train for comparison
• Store-and-forward: data stays on the SD card until the server confirms receipt
• Restarts wait until a train has been fully captured, so no train is lost
• Remote configuration, diagnostics and over-the-air firmware updates
• Grid supply voltage monitoring with alerts

Technical specifications

Controller	ESP32-S3, 8 MB flash, 8 MB PSRAM, FreeRTOS
Axle detection	2 inductive proximity sensors, sampled every 1 ms
Temperature sensing	2 infrared pyrometers (left and right), 16-bit ADC at 860 samples/s, per-side calibration
Capacity	Up to 600 axles per train
Connectivity	4G LTE or Wi-Fi; MQTT for control, HTTP for data upload
Local storage	microSD card, one record per train
Reliability	Watchdog, sensor self-recovery, deferred restart, store-and-forward upload

Railways

LLMG: Live Line Monitoring Gauge

Overview

LLMG is a battery-powered, laser-based gauge that a maintenance crew places across a live broad-gauge track to measure overhead equipment (OHE) geometry, with no power block, traffic block or tower wagon. It rests on both rails through insulated rollers and a spring-loaded rail seat, and shows readings on its own display and in a companion Android tablet app. It is built to RDSO Instruction TI/IN/0046.

Key features

• Measures contact-wire height, stagger, mast implantation and cant
• Automatic cant compensation of height, stagger and implantation on curves
• Optional pantograph displacement calculation
• Red-dot sight with a 90° eyepiece for aiming at the wire in bright sunlight
• Insulated rail rollers, so the track circuit is not affected
• Tablet app saves readings with location and exports them to PDF, Excel or PNG
• Wi-Fi hotspot, Bluetooth configuration and over-the-air updates

Technical specifications

Height, conventional OHE	4500 to 6000 mm, 1 mm resolution, ±5 mm tolerance
Height, high-rise OHE	Up to 7800 mm, ±10 mm tolerance
Stagger	−720 to +720 mm, 1 mm resolution, ±10 mm tolerance
Implantation	2180 to 10000 mm, ±10 mm tolerance
Cant	Measured over the 1676 mm broad-gauge base by a 9-axis IMU
Weight	9.5 kg
Battery	3 × Li-ion 3200 mAh, about 8 hours of use
Protection	IP65; −10 °C to +50 °C operating range
Display and controller	2.4-inch OLED; ESP32-S3 controller

Railways

AIBOHSH

Overview

AIBOHSH (AI-Based OHE Stagger & Height Measurement System) is a roof-mounted camera system that measures contact-wire height and stagger on 25 kV AC overhead equipment while the vehicle is moving. A high-speed industrial camera watches the pantograph and contact wire, GPS tags every frame with its location, and AI running on a GPU laptop in the cab finds the pantograph, wires and masts and turns them into mast-wise inspection reports. It is designed for tower wagons, track recording cars and electric locomotives.

Key features

• Height and stagger measurement for up to 5 OHE wires
• AI detection of the pantograph, contact wire, catenary and masts
• Every frame GPS-tagged and linked to mast locations
• Gradient between masts, relative gradient, and a separate report for gradients over 3 mm/m
• IOL, UIL, graphical and exception reports with PDF export
• Live video view, plus frame-by-frame playback showing the parameters for any frame
• Raw video is always kept, so any run can be measured again
• Installs in under 30 minutes, within the rolling-stock schedule of dimensions

Technical specifications

Operating speed	Up to 160 km/h
Stagger range	±500 mm
Wires measured	Up to 5
Camera	High-speed GigE industrial camera with focus light, IP65 enclosure rated for 3 g shock
Field of view	Full 850 mm pantograph from up to 12 m; at least 1 m of contact wire either side at supports
Positioning	GPS, better than ±1 m
Processing	GPU laptop in the cab running AI inference
Service conditions	Up to 70 °C in sun, 100% humidity, dusty terrain

Railways · Critical Infrastructure

Rockfall Detection

Footage captured at our Dudhsagar installation.

Overview

Railway lines through hilly terrain are exposed to rockfall, landslides and seismic activity. Near Dudhsagar, on the Goa–Karnataka border, a single-line railway that links Goa to the neighbouring states runs along cut mountain ridges protected by safety nets. Rockfall is a real-time monitoring and early-warning system that watches the impact of falling rock and landslides on these nets, helping to avoid accidents and keep trains running smoothly.

Key features

• Real-time monitoring and early warning for rockfall and landslides
• Detects even the smallest trigger events: rockfall, landslides, debris accumulation and seismic activity
• Sensors on the safety nets along the slope
• Data relayed to the cloud through a trans-receiver for analysis and AI
• Data collected and analysed for each terrain, since ground conditions vary widely across India
• Video on demand and over-the-air remote control
• Battery powered with solar charging, for remote sites without mains power
• Designed and built in India

Technical specifications

Site	Single-line railway near Dudhsagar, Goa–Karnataka border
Events detected	Rockfall, landslides, debris accumulation, seismic activity
Sensing	BLE sensor kits on the safety nets: load sensors and IMU (vibration) sensors, plus a climate kit for temperature, humidity and rain
Connectivity	4G / LTE trans-receiver and processing unit sending data to the cloud
Analytics	Cloud analysis and AI, with terrain-specific data
Remote features	Video on demand, over-the-air controls
Power	Batteries with solar charging