In the railway sector, where safety is a key asset, the effectiveness and innovation of safety systems significantly determine the reliability of operations. The International Design Centers (IDC), Elemaster Group’s R&D division, are distinguished by their advanced research and development capabilities, especially in the field of safety engineering. This article explores in detail the various R&D competencies, with a particular focus on the importance of Safety Integrity Level (SIL) and the methodologies adopted to ensure that products not only meet, but exceed the safety and quality standards required by Customers.
R&D Services Overview
Eletech, the Italian engineering division of the IDC, offers a complete range of R&D services according to the ISO 22163 standard, essential to innovate and respond effectively to the challenges of rail transport.
Complete Products Development: Eletech manages the entire product development cycle, from concept design to hardware, software and mechanical one, through to conformity testing. This integrated approach ensures that every aspect of the product is optimised for performance, reliability and safety. The Intellectual Property of the project is fully transferred to the end Customer, including the technical documentation and source files (gerber files, 3D mechanical CAD, SW source code).
Electronic Design and System on Module (SoM): The ability to design schematics, PCB layouts (Printed Circuit Board) and develop System on Module (SoM) is crucial to offer customised and flexible modular solutions. SoM modules are platforms that act as design accelerators, i.e. they enable rapid integration and testing of prototypes, optimising development time, reducing design risks and improving the overall quality of the final product.
IoT platform: The IoT (Internet of Things) platforms represents the cutting edge of technology. They integrate all the capabilities of artificial intelligence, including big data management, machine learning, alarms, telemetry, controlled over-the-air (OTA) updates and predictive maintenance. These technologies make it possible to constantly monitor the status of railway systems, predict faults before they occur and improve operational efficiency.
Compliance Testing Laboratory: The testing laboratory is a key pillar in product certification. EMC (Electromagnetic Compatibility), insulation, climatic, vibration and shock tests tests are accredited in accordance with the internationally recognised standard ISO/IEC 17025:2017, and ensure that products can operate correctly in end-use environments and withstand hostile mechanical and climatic stresses, such as those found in the railway industry.
Rapid Prototyping: thanks to its vertical integration with Elemaster Group services, Eletech can rapidly prototype and manage the industrialisation of new products, a key requirement for maintaining flexibility in the competitive rail sector.
Industrialisation & New Product Introduction (DFM/DFA/DFT): These analyses ensure that products are designed not only to perform well, but also to be easily made, assembled and tested when put into production. Eletech’s many years of experience, synergies with Elemaster’s manufacturing processes and vertical integration with Elemaster’s capabilities ensure that DFx analysis can be carried out early in the project, to ensure that the product architecture takes production constraints into account.
Development of Test benches for Production Testing: this equipment includes ICT (In Circuit Tester), Flying Probe, ATE (Automatic Test Equipment), Burn-in and Functional Test Equipment (FCT). For each product to be transferred to production, the appropriate test strategy is defined, considering various factors such as design complexity, level of test coverage, test time and equipment costs. Eletech has a functional test platform called ELETEST that accelerates equipment development while reducing implementation costs.
Design To Cost / Value Engineering: Optimisation of production processes and reduction of material costs while maintaining the functions the product performs.
Product Maintenance: Replacement of obsolete components and monitoring the availability of device components to ensure continuity of production while avoiding supply chain risks.
Quality Management System
International Design Centers have a Quality Management System (QMS) certified according to ISO/TS 22163 (IRIS standard) for product development in the railway sector. Achieving certification for railway products requires a rigorous testing regime to ensure safety, reliability and interoperability.
The key concept of Safety Integrity Level (SIL)
The Safety Integrity Level (SIL) is a key concept in the design of safe railway systems. SIL is a measure of the risk reduction required to avoid failures that could cause significant damage, such as injury or loss of life, environmental damage or severe economic loss. It is defined by international standards, such as IEC 61508, which regulate the functional safety of electrical, electronic and programmable electronic systems.
SIL-Flex: An Innovation in the Development Process
SIL-Flex is an innovative approach that Eletech has developed to accelerate and optimise the development process of safety systems. This concept involves the use of platforms such as the SIL-Flex Board Accelerator, a carrier board designed to rapidly integrate input and output interfaces that have already been developed and tested, reducing the risk of errors and optimising development time. The platform provides a versatile solution on which to build systems that comply with safety standards SIL0 to SIL4. The carrier board can accommodate up to three System on Modules (SoM), providing the necessary redundancy with two microcontrollers and a third microcontroller acting as an arbiter. This modular design allows easy maintenance and updating, ensuring that the technology can adapt to future regulatory and market requirements.
The Eletech Laboratory: A Pillar of Quality and Innovation
Eletech’s laboratory is instrumental in the development of solutions for railway certification. EMC, climatic, insulation, vibration and shock tests are accredited in accordance with the internationally recognised standard ISO/IEC 17025:2017. This in-house laboratory is equipped with advanced technology and state-of-the-art testing equipment to perform EMC, vibration and climate tests, ensuring that each product not only meets, but exceeds safety and quality standards. The presence of an in-house certified laboratory enables pre-compliance and final compliance testing, significantly accelerating the development and certification process, and maintaining complete control over the quality and reliability of the finished product. This ensures that each system can meet the stringent requirements of the railway industry standards with maximum effectiveness.
Contributions and Impact of R&D in the Railway Industry
The Elemaster Group’s ongoing commitment to research and development constantly raises the standards of safety and efficiency in the railway industry. Advanced integrated systems and IoT platforms improve operations and reduce costs, consolidating safer and more efficient transport. The integration of innovative technologies such as artificial intelligence into predictive maintenance systems allows for continuous monitoring of the status of railway components, predicting failures and optimising maintenance interventions ensuring constant technological advancement that contributes to a safer and more reliable railway sector for everyone.