Zephir S.p.A. is a company specialized in the design and manufacturing of shunters for railway handling operations, operating within the railway mechanical engineering sector. Backed by a strong Italian manufacturing tradition and part of Marmon Holdings, the company stands out for its quality, reliability, technological innovation, and its ability to provide tailor-made solutions and customizations according to specific customer requirements.
Always focused on the evolution of the railway industry, Zephir develops modern and efficient vehicles by integrating the latest technologies to improve safety, sustainability, and operational performance. The following sections will present the company’s main technological innovations and the latest advanced solutions it offers.
Engineering Dual-Gauge Flexibility and Laser-Guided Precision: Innovative Solutions from Zephir and Marmon Rail
Key innovation projects from Zephir, a Marmon Rail company, are pushing the boundaries of shunter versatility, driven by a strategic partnership with the Marmon Rail Innovation department. Two standout, patented technologies—the Dual Gauge Rail Wheel and the Laser Alignment System for Railcar Movers—showcase this commitment to solving complex operational challenges.
Supervised by Marco Mattioli, Vice President of New Technologies at Marmon Rail, these projects leveraged his deep expertise, stemming from his former role as Managing Director of Zephir.
The Challenge of Multiple Track Gauges
Global rail infrastructure is characterized by multiple track gauges, forcing maintenance depots and railyards operating multiple standards to invest in multiple locomotives. This operational inefficiency was highlighted by a key client in Spain, which required servicing both standard (1435 mm) and broad (1668 mm) gauge tracks.
To address this, Zephir and Marmon Rail designed a specialized, patented Dual Gauge Rail Wheel system.
Engineering the Dual Gauge Solution
The innovative solution centres on utilizing the unique capability of Zephir railcar movers to fully lift their rail wheels while in road mode. Leveraging this, engineers designed a specialized sliding mechanism for the wheelsets, complete with mechanical end-locking systems.
This allows operators to easily switch the machine’s gauge configuration while in road mode. For example, a machine can operate on standard gauge, move to road mode, adjust the wheel setting, and immediately on-track to the broad gauge network. This breakthrough allows a single machine to handle diverse network requirements, significantly reducing capital expenditure for infrastructure owners.
Enhancing Operational Efficiency with Laser Guidance
Another common pain point identified through Voice of Customer (VOC) feedback was the complexity of the road-to-rail transition. Misalignment during the transition can lead to improper wheel seating, necessitating a time-consuming restart of the process. While experienced operators manage this well, high-turnover environments or multi-shift operations faced significant downtime.
To eliminate this, Zephir developed a specialized Laser Alignment System.
The system casts high-visibility laser beams from the machine to the ground. The operator simply aligns these beams with the desired rail. Once aligned, the railcar mover reliably lands on the rail in a single, safe motion. Field testing showed that even, inexperienced operators could successfully on-track on their first attempt, significantly boosting operational efficiency and reducing operator fatigue.
Both the Dual Gauge Wheel and the Laser Alignment System are patented, representing a significant step forward in optimizing railcar mover performance and versatility.
