Brake-by-wire: Better, lighter, quieter

The technology completely replaces the pneumatic and hydraulic components that are integral to today’s braking systems with electrical transmission of the braking signal and electromechanical generation of braking force by electric motors.

The more dynamic controllability of the electromechanical brake calipers, for example, delivers significantly improved performance, including faster response times, highly precise brake-force control, and shorter stopping distances. This enhances safety, stability, and reliability in day-to-day rail operations.

At the same time, the system can be made significantly lighter than conventional braking systems due to its reduced number of components, making a substantial contribution to energy savings. Overall, this also reduces the effort required for installation, servicing, and retrofitting, while optimizing the system’s lifecycle costs for operators.

The EM brake is equipped from delivery with telemetric monitoring and diagnostic capabilities, including predictive maintenance functions, and is regarded as a key for enabling more efficient, lighter, and more cost-effective trains. In doing so, it paves the way for the “airless train”: the vision of a train that operates without the compressed-air and hydraulic systems that have been the global industry standard for decades.

“I would like to thank Trenitalia for this valuable collaboration. The rail industry needs innovation more than ever, especially to make rail transport even more efficient and competitive. This project demonstrates just how essential collaboration between operators and industry is to accelerate the transformation of mobility and turning innovation into tangible progress,” adds Simone Mantero, Managing Director of Knorr-Bremse Rail Italy.

A demonstration of the EM braking system, showcasing its wide range of capabilities, is available for visitors to experience live at the Knorr-Bremse booth during InnoTrans (September 22-25, 2026).

State-of-the-art freight solutions

Starting in 2028, the partners will test the technology’s practical features under real-world conditions as part of the EU-funded PioDAC project (Pioneer Digital Automatic Coupling). The ÖBB Rail Cargo Group’s PioDAC train consists of 23 freight cars and one locomotive. Knorr-Bremse will equip the cars with state-of-the-art DAC systems, including electronic control units, and will integrate sensors for the digital monitoring of vehicle functions and conditions. The project builds on several successful previous projects as part of Europe’s Rail.

The DAC enables faster processes for train formation, preparation for departure, and operations at shunting yards, and contributes significantly to greater safety as well as time and cost savings. The technology replaces manual screw couplings with a modern coupling system that, for the first time, establishes continuous power and data connections throughout the entire train. This allows freight trains to be assembled and separated more quickly. In particular, the time-consuming and labor-intensive coupling and uncoupling of cars will be possible at the push of a button or via a tablet – a major relief for staff and operators.

Digital rail freight: A key growth market

Technologies for the automation and digitalization of trains represent a key growth area for Knorr-Bremse, in which the company targets an annual revenue potential for original equipment in the triple-digit million-euro range for Europe. Knorr-Bremse aims to assume a leading role in Europe, particularly with the DAC, which will be gradually introduced to the market over the next few years. In addition to DAC, Knorr-Bremse is focusing on wireless solutions for fleets, such as FreightControl Sentinel, which already offer clear advantages in terms of efficiency and operational optimization, for example, through digital condition monitoring.

Dr. Nicolas Lange, Executive Board Member responsible for Rail of Knorr-Bremse AG: “Together with CARS, we are elevating our long-term partnership in the Chinese railway industry to the next level – from product collaboration to joint development of system-level innovations. China is a key growth market for Knorr-Bremse, and by combining our global expertise with local excellence, we are strengthening our role as a systems partner while shaping the future of efficient, intelligent, and sustainable rail freight.”

From product supply to system-level innovation

Building on more than 20 years of successful cooperation between CARS and Knorr-Bremse, the China Freight Cooperation Program expands the partnership beyond a product-focused collaboration to include broader cooperation on systems innovation level.

Joint efforts to accelerate digitalization and intelligent upgrades of rail freight will focus on multiple technology areas. Freight digitalization will cover digital train architecture, predictive maintenance, wagon monitoring solutions, and digital automatic couplers, which are also being prepared for market deployment in Europe. Apart from coupler-based solutions, the partners will focus on wireless functions running on wagon-bound energy storage to enable enhanced fleet monitoring and service optimization.

In addition, Knorr-Bremse and CARS will develop driver assistance technologies to improve energy efficiency and fleet performances, based on solutions like LEADER that are already in operation in Europe, in the US, and Australia. Besides, the partners will work on advanced braking systems tailored to the demanding requirements of long-distance and heavy-haul transportation.

Upgrading rail freight: A substantial growth market

Modernization of rail freight is gaining momentum worldwide. The most comprehensive and advanced initiatives are currently planned in Europe, where the original equipment market alone is expected to reach approximately €25 billion for the upgrade of up to 500,000 freight cars. As the partner of choice for next-generation technologies across the rail ecosystem, Knorr-Bremse targets an annual revenue opportunity in the mid triple-digit million-euro range in Europe.

China, which operates one of the world’s largest rail freight fleets, is pursuing similarly ambitious modernization and modal shift programs, pointing to a market potential comparable to that of Europe. As the United States, the world’s third major rail market, are expected to adopt next-generation rail freight technologies as well, this positions Knorr-Bremse to capture a global annual revenue potential exceeding €1 billion in the long term.

Route, train, and data: Rail as a holistic ecosystem

At the core of Knorr-Bremse’s integrated wayside portfolio is the scalable ElectroLogIXS platform. Based on a unified hardware and software foundation, Knorr-Bremse presents solutions for three key application areas.

1. Intelligent nerve center: Smart safety technology for interlocking

How do you prevent two trains from using the same route? Every day, countless train movements must be coordinated across rail networks without connections crossing paths or operations interfering with one another. Innovative control and safety technology for interlocking systems, such as the ElectroLogIXS Vital Logic Controller (VLC), handles high-precision train detection, train tracking, and route control, thereby transforming traditional interlockings into intelligent control centers.

2. The smart route: Signals, switches, and railroad crossings at a new level

Is the infrastructure in perfect condition – and what’s happening along the route? To ensure smoother rail operations, track elements such as signals, switches, and railroad crossings must function safely and reliably. Innovative features enable critical infrastructure points to be operated more reliably – and serve as valuable sources of data.

The ElectroLogIXS Object Controller controls and monitors components such as switch actuators, train detection systems, track circuits, and axle counters on a common digital platform. In doing so, it lays the foundation for the modernization of existing networks and helps improve their performance, efficiency, and maintenance planning. Latest-generation LED Compact signals combine maximum optical performance with broad interlocking compatibility and energy-efficient operation.

3. Data & Analytics: Intelligent data analysis for improved operations

How can risks be identified before they disrupt rail operations? Modern signaling and data solutions, such as the Data Acquisition Unit (DAU), collect valuable infrastructure data directly along the track before the Wayside System Data Management Module (WSDMM) analyzes it. This provides operators with profound insights into the condition of their infrastructure, laying the foundation for informed decisions, predictive maintenance, and early detection of malfunctions.

In addition, Rail TempEst offers benefits for rail operations under extreme conditions: The technology measures rail temperature in real time and provides early warnings of potential deformations or rail damage caused by extreme heat or cold, enabling operators to optimize train speed management early-on, adjust schedules, and ensure operational stability.

Meet at Knorr-Bremse: Rail Mobility Visioneers at InnoTrans 2026

Under the theme “Rail Mobility Visioneers,” Knorr-Bremse brings the future of the rail ecosystem to life: at a multi-level booth spanning approximately 1,350 square meters in Hall 1.2, Booth 250, Knorr-Bremse combines its On-Train, Wayside, and X.Sectional portfolios into a comprehensive range of solutions. In-depth insights into the X.Sectional Embedded Electronic Solutions segment will be provided at the Knorr-Bremse special booth of the same name in Hall 27, Booth 740. In addition, Knorr-Bremse is presenting solutions related to the Digital Automatic Coupler (DAK) and the digital-electromechanical braking system at Europe’s Rail (Hall 4.2, Booth 250). At the CityCube (Hall B, Booth 610), the DAK will be the focus of exhibitor Gruppo FS as a key technology for automated rail freight transport.

Increased transport performance and network capacity

Smart vehicles, future-proof infrastructure, and greater digitalization work together to increase performance and capacity on the tracks. At InnoTrans, Knorr-Bremse will demonstrate how modern on-train systems support this transformation.

• The focus is on “Evolution of Braking”: Featured exhibits demonstrate how Knorr-Bremse is advancing its braking expertise into the next generation of technology: The digital-electromechanical braking system, featuring “Brake-by-Wire”, opens up entirely new possibilities for higher performance, improved energy efficiency, and optimized lifecycle costs through full electrification and the complete elimination of hydraulics. At the same time, Knorr-Bremse is continuously advancing the development of the electropneumatic brake (“Brake-by-Air”), which is currently the global standard for train braking systems. The new nX system architecture lays the foundation for this: It enables software-defined solutions and the integration of customer-specific, data-driven functions in an environment with the highest safety requirements. The technologies presented demonstrate how Knorr-Bremse is advancing different, future-driven lines of development for rail braking systems.

• With Future Rail Freight Transportation, Knorr-Bremse highlights the potential of the Digital Automatic Coupler (FreightLink) as an enabler for automated and digitized freight transport. The DAK Type 5, featuring the Knorr-Bremse e-Coupler, provides the foundation for automatic coupling and functions such as automatic brake testing, train formation, and remote uncoupling through a train-wide data and power connection. Together with the FreightControl Suite and FreightControl Sentinel, it enables automation architectures for the Digital Freight Train – ranging from DAK-based solutions to wireless concepts. For passenger rail, Knorr-Bremse offers solutions such as the proven front- and center-buffer couplers AutoLink and ShortLink.

• The LEADER Flow driver assistance system for freight transport uses real-time traffic and route data to provide predictive driving recommendations. As a result, trains operate more energy-efficiently and achieve savings in the double-digit percentage range. The system is already supporting customers in their daily operations. In addition, LEADER AutoControl – which is in use in the U.S. and Australia, among other places – optimizes energy consumption, braking performance, and operational efficiency for the heaviest freight trains and, through automation and assistance functions, contributes to more economical and efficient rail operations.

Optimized Ecological Footprint for vehicles and fleets

Rail is already one of the most sustainable modes of transportation. Innovative vehicle technologies can make it even more environmentally friendly and energy-efficient. Using a holistic approach, Knorr-Bremse reduces energy consumption, resource use, and emissions throughout a vehicle’s entire life cycle.

• Sustainable Friction Pairing is a holistic approach to sustainability across the entire life cycle of the braking system: Matching the brake pad and brake rotor to the overall system helps optimize the CO₂ footprint, particulate matter emissions, material compliance, circular economy, and energy efficiency during operation. Depending on the application, different material combinations and design variants can offer the best possible solution in terms of performance and sustainability.

• Intelligent Compressed Air Supply: AirSupply Smart adjusts the air supply to the braking system based on demand, making it quieter and more energy-efficient. Together with the ScrewSupply Eco compressor and the DrySupply Compact air dryer, the system reduces noise emissions, maintenance requirements, weight, and space requirements. At the same time, the new ScrewSupply Eco reduces lifecycle costs by up to 40 percent.

• The Smart Integrated Functional Unit (SIFU) also contributes to intelligent energy management. It combines control, diagnostic, and measurement functions for energy distribution into a single compact system. The measurement technology provides transparency into energy flows, helps operators optimize energy consumption, and can reduce the amount of wiring required on board by more than 70 percent. A new addition is the SIFU AC variant for alternating current vehicles.

Better and more comfortable travel: Passenger Comfort

Comfort, accessibility, and availability are all interconnected in rail transportation. Knorr-Bremse combines modern technologies and digital services to create solutions that make travel easier for passengers and enable operators to run their fleets more efficiently.

• For regional and commuter trains, Knorr-Bremse presents the ZeroStepBoarding system in combination with the E4 double-leaf door system. With a door threshold reduced to as little as nine millimeters, it enables virtually step-free boarding and alighting and meets the strict European and American accessibility requirements. Contactless boarding via the TouchlessBoarding sensor and the ProDect 2S anti-pinch system further enhance safety and comfort while helping to reduce stop times. At the heart of the boarding system is the Select door control unit. It integrates door control with cybersecurity as well as digital service and maintenance functions such as condition monitoring and digital maintenance. This ensures transparent monitoring of system status and maintenance requirements.

• Sanitary systems are among the mission-critical components in rail transport. The Next Generation Toilet (NGT) monitors operational data such as vacuum and pressure buildup as well as tank levels in real time, laying the foundation for intelligent diagnostics and condition-based maintenance. This enables early detection of malfunctions, reduces downtime, and increases vehicle availability.

X.Sectional: The intelligence layer of the rail ecosystem

Smart on-train systems taken to a new level: With X.Sectional, Knorr-Bremse combines embedded electronic solutions, state-of-the-art software, and expertise in train communication and control technology. Real-time data exchange ensures that the train, track, and operations management work together seamlessly, making operational processes more efficient.

• Embedded Electronic Solutions combines the expertise of the Duagon and Selectron brands into a portfolio covering electronics, computing, control, communication, and new software developments for vehicles and their surroundings. At InnoTrans, Knorr-Bremse will showcase, among other things, solutions in the areas of Computing & Control and Train Control Network.

• Digital Solutions harness the potential of vehicle and infrastructure data through intelligent analysis and AI, providing in-depth insights into condition and performance. Solutions from Railnova, for example, make better use of fleet telemetry data and leverage intelligent analytics and AI, accelerate remote diagnostics and maintenance. At the same time, Knorr-Bremse is one of the driving forces behind the European Rail Data Space, a secure data platform that enables sovereign data exchange across operator, manufacturer, system, and national boundaries.

• With RailServices, Knorr-Bremse supports customers throughout the lifecycle of their fleets. Modernization, component maintenance, and refurbishment extend service life, conserve resources, and improve availability. Together with digital partner EYYES, Knorr-Bremse is introducing the AI-powered driver assistance system RailEye Front Collision Warning for metro, tram, and light rail operations. Intelligent cameras detect obstacles and people in the track area and alert train operators. If no response is received, the system can trigger automatic braking.

Meet at Knorr-Bremse: Rail Mobility Visioneers at InnoTrans 2026

Under the theme “Rail Mobility Visioneers,” Knorr-Bremse brings the future of the rail ecosystem to life: at a multi-level booth spanning approximately 1,350 square meters in Hall 1.2, Booth 250, Knorr-Bremse combines its On-Train, Wayside, and X.Sectional portfolios into a comprehensive range of solutions. In-depth insights into the X.Sectional Embedded Electronic Solutions segment will be provided at the Knorr-Bremse special booth of the same name in Hall 27, Booth 740. In addition, Knorr-Bremse is presenting solutions related to the Digital Automatic Coupler (DAK) and the digital-electromechanical braking system at Europe’s Rail (Hall 4.2, Booth 250). At the CityCube (Hall B, Booth 610), the DAK will be the focus of exhibitor Gruppo FS as a key technology for automated rail freight transport.