1) Introduction: Availability as a Key Operational Indicator

For regional rail operators, fleet availability is often constrained by frequent wheelset maintenance rather than vehicle age. Railway wheelsets operating on routes with frequent stops, variable speeds, and tight curves are prone to accelerated tread wear and alignment issues. Improving wheelset durability has become an effective way to enhance service reliability without major infrastructure investment.

2) Application Scenario: Regional Wagons with Frequent Start-Stop Cycles

This application focused on wagons used in regional logistics services, operating across industrial zones and ports. The service pattern involved frequent acceleration and braking, resulting in higher thermal and mechanical stress on wheelsets. Existing wheelsets required frequent reprofiling, increasing downtime and maintenance costs.

The operator identified several pain points:

• Short wheel reprofiling intervals

• Increased noise and vibration in curves

• High dependency on workshop capacity

3) The Kingrail Solution: Wheelset Adapted to Regional Operating Patterns

Kingrail developed a customized railway wheelset solution based on the specific duty cycle of the route. Wheel material selection emphasized resistance to surface fatigue, while wheel profiles were chosen to improve contact behavior on curved track sections. Axle design and bearing selection were matched to the stop-start operational pattern.

Solution highlights included:

• Optimized wheel tread profiles to reduce localized wear

• Axle design supporting stable load distribution

• Wheelset assembly aligned with international railway standards

Kingrail worked closely with the operator to ensure the wheelset configuration supported both performance and maintenance efficiency.

4) Results and Operational Improvements

Following implementation, the operator reported smoother running behavior and reduced wheel noise in curves. Wheel wear progressed more gradually, allowing longer intervals between reprofiling. Maintenance teams benefited from more predictable inspection cycles and reduced emergency interventions.

Key improvements included:

• Higher wagon availability during peak operating periods

• Lower maintenance intensity per wheelset

• Improved ride stability across the network

While results varied depending on route conditions, the wheelset solution delivered clear operational improvements in many service scenarios.

5) Conclusion: Practical Wheelset Upgrades for Regional Operations

This application demonstrates how targeted railway wheelset optimization can improve performance in regional rail services. The solution is especially valuable for operators managing frequent stop-start operations and limited maintenance windows. As a long-term solution provider, Kingrail supports customers in evaluating existing wheelset performance and developing tailored upgrade strategies.