Maintenance costs 50% of a train's lifetime. Without data, you're flying blind.
Every day, hundreds of thousands of kilometers are driven by rail. We help you use each of them to learn, improve, and predict. Using conventional methods gathering this data has been too expensive, too slow, and too disruptive.
We built a better way.
OUR INNOVATION
No structural modifications. No downtime. No taking the train off the tracks for weeks. Mount it externally and start collecting data within the same shift.
The alternative takes weeks, costs a fortune, and requires modification of your components. Zyglox sensors take 30 minutes to install and leave everything intact.
Every kilometer driven becomes a data point. Trend analysis, anomaly detection, real-time load monitoring — the foundation for condition-based maintenance and an expected 10–15% reduction in maintenance costs.
THE CHALLENGE
Strain gauges and instrumented wheel-sets require weeks of installation, structural modifications to your components, and break down under long-term field conditions.Great for short test windows. Not for continuous monitoring.
The result of missing data: Over-engineered components. Maintenance runs on schedules, not on condition. Problems are discovered at the next inspection — not when they happen.
HOW IT WORKS
ZYGLOX TURNS THE AXLE INTO ITS OWN SENSOR
Mechanical stress changes the magnetic permeability of ferromagnetic materials. Our patented sensors detect these changes without contact — no modifications, no wear, no ongoing maintenance on the sensor itself.
The result is a perfectly linear, history-independent stress measurement that matches the precision of strain gauges, nstalled in 30 minutes, running continuously.
ACTIVE MAGNETOELASTIC MEASUREMENT
Unlike passive magnetostriction — which is non-linear, hysteresis-prone, and unreliable for safety-critical use. Zyglox uses active excitation. Zero hysteresis. Precision data on every rotation.
Signal depends on the metal's magnetic history. Non-linear. Unreliable for safety-critical measurement.
Perfectly linear. History-independent. Precision matching DMS strain gauges.
WE deliver
Enable condition based maintenance. Schedule fewer inspections by safely extending maintenance intervals. Reduce over-engineering.
Detect anomalies when they occur — not weeks later at a scheduled check. Act on condition, not on calendar.
YOUR BENEFIT
Continuous data from every equipped axle, across every rotation. No gaps between inspections. No oeprational blind spots.
Know when a component is trending toward failure before it fails. Fewer surprises. Fewer unplanned stoppages.
Detect anomalies when they occur — not weeks later at a scheduled check. Act on condition, not on calendar.
FOR WHOM
RAILWAY OPERATORS
Shift from time-based to condition-based maintenance. Fewer delays. Fewer unexpected failures.
Extend inspection intervals based on actual load data
Make operational decisions with confidence
Reduce unplanned downtime
MANUFACTURERS
Know what your components actually experience in the field. Build the next generation with real data. And when something fails — know whether it's your component or the track.
Reduce warranty risk with continuous load records
Improve component design based on real-world stress data
Deliver more with less over-engineering
OUR SYSTEMS
Non-invasive monitoring for hollow shaft axles. Measures stress distribution in real time across every rotation. Permanently installed, continuously running.
Quality assurance for press-fit connections. Detects hidden defects that conventional methods, including standard press-fit curves, miss entirely.