The Solution: Wheelset Machining Directly at the Facility
The answer is straightforward: wheelset machining must take place where the vehicles are. With the installation of an underfloor wheel lathe (URD), this is becoming a reality in Haltingen. The machine measures and machines wheelsets while they are still installed in the vehicle—precisely, efficiently, and without additional replacement and transport procedures or transfer movements. What sounds simple and logical fundamentally transforms the entire workshop process in practice. The path to this goal involved a challenging infrastructure project in which DB Systemtechnik took the lead in planning the facility.
The Approach: Designing a Comprehensive Production System
In close collaboration with DB Regio, DB Systemtechnik has been supporting the project since 2022—with the goal of not only installing technology but also creating a functional, integrated solution. After all, an URD only realizes its full potential when it is seamlessly integrated into the infrastructure, processes, and systems, and its performance characteristics are tailored to local production requirements.
Our contribution—from concept to initial machining
The path to the finished system begins long before it is first put into use.
Laying the Groundwork
Initially, the site was analyzed in detail, including via 3D scanning. Based on this analysis, the machine position, pit geometry, and all technical requirements were defined to ensure that the machine and its surroundings are optimally matched.
Selecting the Right Technology
The request for proposals was not just about a single machine, but about the entire system. DB Systemtechnik developed the technical requirements, structured the evaluation process, and provided detailed support throughout the award decision.
Integration Instead of a Standalone Solution
An URD requires careful specification, configuration, and detailed integration into the production environment: the surrounding infrastructure, tow vehicle, crane system, utility connections, and the machine itself were developed into a coordinated system through the involvement of additional trades. Integration into IT systems—such as the data connection to the SAP system or the capability for remote maintenance—also had to be specified, with implementation supported and tested prior to commissioning.
When Theory Becomes Practice
At the manufacturer’s facility, the system underwent comprehensive testing after production (known as a factory acceptance test). This was followed in Haltingen by assembly, commissioning, geometric inspection, and calibration, as well as a measurement uncertainty analysis. The subsequent trial operation will demonstrate whether the entire system is fully functional.
This is precisely where DB Systemtechnik closely supports the site and is now carrying out the corresponding acceptance tests and approvals.
People Make the Difference
Technology alone is not enough. That is why the workshop staff was involved early on and received targeted training from DB Systemtechnik. Several operator training sessions ensure that the system can be used safely and efficiently from day one and that the turners have a solid foundation of knowledge to draw upon.
Technology and Processes Working Together
With the new URD, more than just a machine is being created in Haltingen. It is a new, integrated maintenance and production facility for one of the most important railway components, where lathe operators, the machine, and the surrounding infrastructure form a single system.
Result: Turning a Bottleneck into a Strength
With the URD’s commissioning in 2026, the workshop’s capabilities will expand significantly. Wheelset machining will take place directly on site. Transfer movements will no longer be necessary, response times will decrease, and the workshop will become significantly more attractive and flexible. What was previously a bottleneck limiting fleet performance becomes a strength of the location.
Added Value for DB Regio Haltingen
Higher vehicle availability through on-site machining
Elimination of transfer movements and reduced downtime
Modern, ergonomic, and efficient work environment
Sustainable development of expertise through targeted training
High appeal for third-party customers in the region
Conclusion
With the new URD, Haltingen is evolving into a high-performance and future-proof maintenance facility. DB Systemtechnik not only provided the expertise but also ensured that processes, systems, and people work together optimally, thereby helping to transform an operational bottleneck into a sustainable strength.
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