Robot and process controllers
Cells shipped Railira-ready, with the targets, limits and envelope declared at the factory. The agent runs on the OEM cell; the OEM keeps the equipment relationship.
Partners
The channel is the equipment.
Railira's distribution plan runs through the companies already on the plant floor: welding and coating robot OEMs, PLM and MES vendors, metrology, torque, wiring-test and brake-test vendors and the integrators who connect them. The programme opens with the design-partner cohort; nothing here is a signed partnership.
Illustrative scenario: Car 07 of a 4-car metro consist · shell line B · bogie shop · booth 2 · marriage station, one car, one approval gate
Partner types
Who fits, and how
How each kind of partner fits the plan.
Work packages, sequencing, genealogy
Genealogy and schedules written back into the system of record. Evidence packets for acceptance and IRIS audits.
Laser trackers, scanners, cameras
Station data fused into Carbra and Fitura. The vendor keeps the measurement; Railira adds the prediction, the root cause and the cited disposition.
Torque tools, wiring testers, brake-test rigs, commissioning systems
Traces and results fused into Bogira and Quality-and-Anomaly. The vendor keeps the tool; Railira adds the escape prediction and the record.
OT, plant networks, robot cells
Connection, target inventory and the shadow-mode phase of a pilot, delivered by people the plant already trusts.
Design partners
The first two to four plants shape the roadmap and get written access terms. See the customers page.
How it works
What a partner does and gets
The outline of the programme as planned.
A partner does
- Declares the targets, limits, envelopes and interfaces on the systems they ship or support
- Co-delivers the shadow-mode and assist-mode phases of a pilot
- Brings a plant with a metric and a signed baseline
A partner gets
- A Railira-ready designation for the cell, station or system, once the connector is proven
- A share of the Process and Plant subscription on plants they bring
- Early access to the SDK and the twin for their own engineering
Integrations
It speaks plant, not cloud
Railira reads and writes through the systems already on the floor. No rip and replace, no parallel historian, no new HMI to learn. Vendor names are examples of systems found in rolling-stock plants, not certified integrations; connector availability is confirmed per site.
Rail PLM, MES and sequencing suites (Siemens Teamcenter, Opcenter and Tecnomatix, Dassault DELMIA, Rockwell, iBASEt, Critical Manufacturing class systems)
Work packages, control plans, sequence reads; genealogy and schedule write-back
Robot controllers and process controllers (FANUC, KUKA, ABB, Yaskawa, Comau, Dürr, Kawasaki class systems)
Parameter and path reads; bounded parameter and sequence recommendations
Laser trackers, point-cloud scanners and vision systems (Hexagon, Zeiss, FARO, Cognex, ISRA Vision, Perceptron class systems)
Geometry scans and inspection results per car
Torque tools and controllers (Atlas Copco, Bosch Rexroth, Stanley class systems)
Torque traces per joint, rework routing
Wiring testers, brake-test rigs, traction-test and ETCS, ERTMS or PTC commissioning systems
Continuity, brake and signaling results per car
Booth instruments, thickness gauges, environmental sensors, recipe systems
Film build, flash, cure, humidity and temperature
Plant-simulation and twin tools (Siemens Tecnomatix Plant Simulation, Dassault DELMIA, Visual Components)
Model and result exchange with the train-and-plant twin
Fleet managers and dispatch APIs
Fleet state, dispatch recommendations
Run timeline · scenario
One scenario run, step by step
Every Railira run is an ordered, inspectable sequence. This is run_9b4e27: Car 07 of a 4-car metro consist · shell line B · bogie shop · booth 2 · marriage station. Scenario completes in 10 steps with one approval gate. Shell geometry held inside tolerance after a twin-ranked weld sequence, one heat-input change approved by the shift weld engineer, two torque traces routed to rework before brake test, the livery cure window protected in the sequence, marriage interface inside tolerance, car released with full genealogy.
run_9b4e27
car 07 · 4-car metro consist
illustrative scenario
SUCCEEDED
-
01
ingest.order
SUCCEEDED
0.8 s
Plant Orchestrator · Pulled the work packages for car 07 from MES and PLM: aluminium extrusion shell, EN 15085 weld class per joint, control-plan geometry tolerances, bogie torque specifications, livery recipe and cure window, fit-out and marriage sequence. Locked the approved control-plan envelope for the shift.
-
02
takt.sequence
SUCCEEDED
41 s
Line-and-Logistics · Sequenced the shift against live readiness: booth 2 cure window, bogie B-14 readiness, brake-test slot at 13:40, AMR fleet state and kit inventory. The plan moves car 07 marriage behind car 06 to keep the cure window and the test slot.
-
03
twin.simulate
SUCCEEDED
58 s
Train Twin · Simulated 18 candidate weld sequences for the roof-to-sidewall joints on the as-built twin and ranked them on predicted distortion, door-aperture geometry and heat input. Sequence #6 keeps the aperture inside tolerance with 2% less heat input than the standing sequence.
-
04
weld.sequence
SUCCEEDED
3 m 12 s
Weld-and-Structure · Recommended sequence #6 and the matching clamping plan to the shell line. Seam vision and laser-tracker geometry confirmed the roof-to-sidewall joints inside the control-plan tolerance on the first four seams.
-
05
approve.human
APPROVAL
52 s
Plant Orchestrator · Sequence #6 lowers heat input on the roof joints 2% below the standing weld procedure. Heat-input changes stay with a named engineer, so the step was held for the shift weld engineer and approved at 06:12:44 with the twin evidence attached.
-
06
bogie.torque
SUCCEEDED
continuous
Bogie-and-Running-Gear · Press-fit curves and torque traces on bogie B-14 read at the station. Two traction-motor mounting traces fell outside the expected profile and were routed to rework before brake test; the remaining safety-critical joints verified to spec.
-
07
coat.cure
SUCCEEDED
continuous
Coat-and-Livery · Booth 2 humidity and temperature, film thickness and flash time watched through the livery pass. One masking misalignment on the door band flagged by booth vision before the second coat; the cure window held and handed to the sequence as a hard constraint.
-
08
marry.align
SUCCEEDED
2 m 05 s
Marry-and-Couple · Carbody and bogie scans compared against target interface geometry before the lift. Fit-out readiness confirmed by Fitout-and-Interior for doors and glazing. Marriage guided inside tolerance; coupler and gangway checks verified and written to the twin.
-
09
inspect.fuse
SUCCEEDED
continuous
Quality-and-Anomaly · Weld and coating vision, in-line metrology, torque, wiring continuity and brake-test results fused at the edge across the car. Every finding localised to station, work package and shift, with the two torque reworks and the masking flag already closed.
-
10
car.release
SUCCEEDED
1 m 30 s
Conformance · Car 07 released: genealogy written (weld records per joint, geometry scans, torque traces, coating recipe and cure record, fit-out checks, marriage interface, approvals, test results) and dispositioned against the control plan and IRIS / ISO/TS 22163 criteria with cited evidence for the quality engineer's sign-off.
Accelerated computing
Physical AI, at the station
A seam is welded in seconds and a booth cannot wait for the cloud. Perception has to be local, deterministic and fast, so Railira runs GPU inference at the plant edge and keeps training, simulation and optimisation in the cloud or on-prem.
Edge perception
8 to 32 cameras per process area plus metrology, torque, thermal, robot and booth-instrument streams fused at the plant edge. Sub-50 ms weld and seam alerts and sub-150 ms coating and metrology prompts are the design targets. Jetson Thor is planned for higher sensor density.
Model serving
Weld-defect, geometry-risk, coating-risk, point-cloud and takt-risk models served at the plant edge with per-model versioning and rollback, routed by latency, tenant, sensitivity and cost.
Training
Weld and coating defect vision, metrology classification, control-plan reasoning and FEA-surrogate models fine-tuned on plant data and engineer corrections. 100 to 500 GPU-hours per plant during onboarding is the design target; dedicated capacity is planned.
Train-and-plant twin
As-built carbody, coating, marriage and line-flow twin. Weld distortion, geometry build-up, robot reach, coating coverage and layout simulated before the shift. GPU FEA and point-cloud metrology are the workloads; OVX scale is planned.
Synthetic data
Rare weld defects, coating contamination, geometry deviations, occluded seams and torque-escape cases generated and validated against real inspection distributions before promotion. Planned.
Optimisation
Line sequencing, JIS feeding, AMR and AGV routing, buffer management and commissioning-slot scheduling against live readiness.
Robot cells
Robotic weld, coating and assembly cells and AMR or AGV flow; path variants validated in simulation before release to the floor.
GPU ETL
Telemetry features from weld parameters, metrology, coating readings, torque, non-conformance and takt history for retraining, drift detection and network analytics.
FAQ
Straight answers
The questions plant directors, body and coating engineers and quality leads ask in the first meeting.
Only within an explicit tool allow-list with per-tool rate and magnitude limits, inside the approved control-plan envelope, and only at the autonomy level your plant has set. Design partners start in shadow mode, where Railira writes nothing. Heat-input and weld-sequence changes, schedule release and car release stay with a named approver.
Control returns to the robot, PLC or station's last known-good state. Railira is a supervisory layer on top of the controllers, safety systems and interlocks you already run, never a replacement for them, so an outage degrades the line to its current way of running, not to a stop.
Recommendations start from the control plan, the work instructions and the twin in the first weeks. Weld, geometry, coating and torque prediction improve as line history and labelled outcomes accumulate per car type. Onboarding is sized at 100 to 500 GPU-hours per plant and 50,000 to 250,000 synthetic images or scan variants per program, all design targets.
Only if you choose cloud training. Designs, control plans, program data, process models and quality records are isolated per tenant and never used to train another customer's models. Fully on-prem deployment at the plant edge is available for regulated plants, and cross-plant learning is planned and waits on data-rights agreements.
You are, the same as with any control strategy, which is why every write is policy-checked, bounded, logged and reversible, and why anything above your risk threshold waits for a named approver. The audit log records the request, the evidence, the envelope applied and the human decision.
A paid pilot on one process or line area, scoped to a single wedge with a success metric written into the order form: weld or coating rework reduction, geometry escapes, torque escapes, line stoppage minutes or first-time-through. It starts in shadow mode against a baseline from your own records, moves to assist mode when the engineer is satisfied, and expands only after the number moves.
Get started
Talk about partnering
Tell us what you ship or support and which plants run it.