EN 15085
The European standard for welding of railway vehicles and components. Carbra works to its weld classes per joint and cites it in every disposition; citing it is not holding a certificate.
Resources
The vocabulary of the plant, and what a pilot needs.
A glossary of the terms Railira's agents work with, the standards the reasoning layer cites, and the inputs a plant brings to a pilot baseline. No white papers or calculators are published yet; this page is the reference we actually have.
Standards the reasoning layer cites
- EN 15085: welding of railway vehicles and components
- EN 12663 and EN 15227: structural fatigue and crashworthiness intent, as design sensitivities
- IRIS / ISO/TS 22163: rail quality management and traceability
- TSI, AAR and APTA: safety and interoperability requirements by region
- Your control plans, PFMEA, torque and wiring specifications, brake-test procedures and coating standards
Retrieval is tenant-isolated and every answer carries its citation. Citing a standard is not a certification claim.
Glossary
Twelve terms
The terms that appear throughout the site.
Carbody
The welded shell of a rail vehicle: roof, sidewalls, underframe and end walls, in steel or aluminium extrusion. Its geometry decides whether doors, glazing and the bogie interface fit later.
Bogie
The running gear under a rail vehicle: frame, wheelsets, axle boxes, suspension, brakes, traction motors and gearboxes. Safety-critical, and judged at brake test and ride-quality runs.
Press-fit
Pressing a wheel or bearing onto an axle. The force-against-displacement curve is the record of whether the fit is right; Bogira reads it per wheelset.
Marriage
Lowering the carbody onto its bogies and connecting them. The interface geometry has to be right before the lift, not discovered after it.
Livery
The exterior paint scheme and protective coating system of a rail vehicle, including anti-graffiti and anti-corrosion layers, applied to the operator's class-A standard.
Cure window
The time and environmental conditions a coat needs before the next coat or the next move. Coatyx watches it and hands it to Taktos as a constraint.
Takt
The cadence a line moves at. On a long-cycle, variant-rich line, one late bogie or curing car breaks it; Taktos sequences against live readiness to hold it.
JIS
Just in sequence: kits fed to the station in the order the cars arrive. One missing harness stops the station.
IRIS / ISO/TS 22163
The rail industry's quality management standard. Railira's genealogy and disposition records are built to be cited against it, not to claim certification to it.
Commissioning
Bringing a finished car to life: brake and traction tests, signaling (ETCS, ERTMS or PTC) commissioning, dynamic ride-quality runs and haul tests. Taktos schedules the slots.
Genealogy
The record of a car: weld records per joint, geometry scans, torque traces, coating recipe and cure, fit-out checks, marriage interface, approvals, test results and disposition.
Pilot baseline
What a plant brings to the first meeting
The inputs for a baseline agreed in writing.
About the process
- Process or line area, the car types it builds and their control plans
- PLM, MES, robot, metrology, torque, test, booth and AMR systems installed, with interfaces
- Quality system and how cars and work packages are recorded
- Shift pattern and who approves weld, coating and sequence changes
About the losses
- Weld rework and geometry escapes per car, by joint and station
- Repaint and coating rework per car
- Torque and press-fit escapes found at test or in service
- Line stoppage minutes and takt loss per shift
- Quality-gate holds and acceptance delays
Reading
Where to go next
The pages that explain the mechanics.
Six layers, one loop
How the plant-edge runtime, orchestrator, agents, twin and cloud loop fit together.
How software is allowed to touch a line
The write path, the audit record and the data governance.
Three labelled walk-throughs
What a pilot on weld and geometry, bogie torque or livery and cure would do and measure.
Writing on rolling stock and autonomy
A stopped line rents by the minute, autonomy as a dial, hit quality and takt before the shift.
Typed tools, declared limits
The SDK and CLI design previews.
Per process, per plant, per network
Tiers, the comparison table and the arithmetic a plant runs.
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.
Autonomy
Four levels, set per agent and per tool
A rolling-stock plant does not go from manual to unattended in one step. Railira makes the level explicit, auditable and reversible at any time. The first release runs shadow mode, then assist mode, then bounded autonomy on low-risk actions. Weld parameters, schedule release and car release stay with named humans until acceptance is earned.
| Level | What the agent does | What the human does | Where it sits in a pilot |
|---|---|---|---|
| L1 · Shadow | Reads weld, metrology, torque, coating, wiring, test, robot and MES signals; predicts and recommends; writes nothing | Runs the line as today; compares predictions to inspection and engineer outcomes | Shadow mode; baseline measured from the plant's own records |
| L2 · Assist | Proposes weld-sequence, geometry, coating, torque and sequencing moves with evidence, confidence, envelope and rollback path | Approves each move in the review console | Assist mode; accuracy and ROI proven against the baseline |
| L3 · Bounded | Executes pre-approved low-risk actions: inspection routing, rework priority, kit feeding, robot path variants and parameter adjustments inside approved bounds | Approves heat-input and weld-sequence changes, schedule release and car release | Graduated autonomy, after audited accuracy and ROI and safety gates |
| L4 · Scaled | Supervised weld-parameter adaptation inside pre-approved control-plan envelopes, across lines and plants | Sets the envelope; reviews the shift record and the evaluation results | Planned; after IRIS, plant and OEM acceptance is earned |
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
Bring the inputs, we bring the baseline
Start with one carbody, bogie, coating, fit-out or sequencing process and one measurable baseline. A paid pilot on weld and geometry, torque assurance, livery defects or line sequencing shows the number before you commit further.