zentrak UNISTAR HR: Reliable switch setting system for demanding operating conditions

2026-10-06 |

Whether facing extreme weather conditions, limited space in tunnel installations or heavy passenger and freight traffic, infrastructure operators are challenged every day to ensure high availability and reliability of their turnout assets while planning maintenance activities efficiently. With UNISTAR HR, voestalpine Railway Systems offers a switch setting system specifically designed to meet these requirements. In combination with zentrak SWITCH CONDITION MONITORING, the solution provides transparency into asset condition and enables data-driven maintenance. Maintenance activities can be planned more effectively, unplanned interventions reduced, and asset availability sustainably improved.

A robust solution for demanding railway networks

UNISTAR HR has been developed to meet the most demanding requirements of railway operations. The switch setting machine system has proven its performance on heavy-haul routes as well as in metro, urban and mixed-traffic networks.

Its robust design ensures reliable switch actuation and high availability, even under extreme operating conditions. The system has demonstrated its reliability for many years across a wide range of climate zones, from subarctic regions with snow and frost to humid tropical environments and desert areas characterized by arid conditions and significant temperature fluctuations.

Maximum flexibility in space-constrained environments

The modular design of UNISTAR HR, featuring separate drive, detection and locking units, offers a high degree of installation flexibility. Depending on local conditions, the drive unit can be positioned between the rails, alongside the track or mounted on a tunnel wall, enabling space-saving integration and supporting planning decisions in even the most demanding infrastructure projects.

Key advantages at a glance

Flexible installation options: Installation is possible both between the rails and alongside the track, making the system ideal for infrastructure projects with limited available space.
High adaptability: A central hydraulic unit, capable of operating up to four operating levels, enables various system configurations and facilitates integration into different track and superstructure designs.
Easy integration into existing infrastructure: Thanks to standardized interfaces, the system can be seamlessly integrated into existing railway infrastructure and interlocking systems.
Robust and reliable technology: The durable design is certified to IP67 and IP68 protection standards, ensuring long-term reliable operation even under demanding environmental conditions.
Reduced installation and maintenance effort: The system’s low weight and excellent accessibility simplify installation and reduce the equipment and resources required for maintenance activities.
User-friendly operation: Simple manual operation in the event of a fault saves time and reduces personnel requirements.

Proven in practice

The reliability of UNISTAR HR under demanding operating conditions is demonstrated by its deployment on the Quebec North Shore and Labrador Railway (QNS&L) in Canada.

The approximately 414-kilometre heavy-haul railway connects remote mining regions with a major port on the St. Lawrence River and is used to transport large volumes of iron ore and other raw materials. Operating conditions present significant challenges for the railway infrastructure: extreme cold, snow and ice, combined with remote track sections that are difficult to access and, in some cases, can only be reached by aircraft or helicopter.

To ensure reliable operations under these conditions, QNS&L has relied on UNISTAR HR since 2016. A specially designed heating system for the drive unit, together with customer-specific modifications, helps maintain high system availability even during subarctic winters. The result is reduced maintenance effort, increased reliability and the smooth transportation of goods along the entire logistics chain.

Maximum availability through intelligent switch diagnostics

Reliable switch setting systems are the foundation of stable railway operations. Even greater potential can be unlocked when the condition of a turnout is continuously monitored.

This is where zentrak SWITCH CONDITION MONITORING comes into play. Combined with the proven UNISTAR HR switch setting system, it forms zentrak UNISTAR HR – an integrated solution that combines robust switch setting technology with intelligent condition monitoring.

zentrak UNISTAR HR continuously captures relevant condition and operating data from the turnout and detects changes or irregularities at an early stage. This enables potential issues to be identified before they lead to disruptions or failures. Maintenance activities can be planned more effectively, and resources can be utilized more efficiently.

Benefits at a glance:

Early detection of anomalies and potential failures
Reduced unplanned disruptions and improved asset availability
More targeted and efficient maintenance activities
Support for condition-based maintenance strategies
Flexible retrofitting of existing installations
Compatible with infrastructure regardless of manufacturer or technology

In this way, reactive maintenance can be transformed into a proactive, condition-based maintenance approach.

With UNISTAR HR, voestalpine Railway Systems offers a robust and flexible switch setting system for demanding railway applications worldwide. Whether on heavy-haul railways in subarctic environments or infrastructure projects with limited installation space, the system delivers reliability, easy integration, and reduced maintenance requirements.

Combined with zentrak SWITCH CONDITION MONITORING, zentrak UNISTAR HR extends these capabilities with intelligent condition monitoring, helping operators improve maintenance planning and make more efficient use of resources.