Final sprint to series production maturity

The German Federal Ministry for Digital and Transport (BMDV) has provided an additional 8.25 million euros in funding, which brings total funding for the research project to 30 million euros.

In June 2020, the BMDV gave the go-ahead for the ‘DAC demonstrator’ research project. The ministry commissioned the DAC4EU (Digital Automatic Coupling for Europe) consortium, consisting of Deutsche Bahn AG, DB Cargo AG, Swiss SBB Cargo AG, Austrian Rail Cargo Group and the wagon keepers Ermewa SA, GATX Rail Europe and VTG AG, to carry out the project. The results of the tests are intended to serve the European DAC Delivery Programme (EDDP) as a basis for the future DAC standard. Until now, manually operated screw couplings have been used exclusively in European rail freight transport - a very time-consuming process which is not without risks for shunting personnel.

Test runs to reach the goal

The first test phase consisted of subjecting various prototypes of DAC couplers from different manufacturers such as Voith, Dellner, Wabtec and CAF to extensive practical tests. In the second phase, the demonstrator phase, DAC was sent all over Europe for test runs under different geographical and climatic conditions in a demonstrator train consisting of tank wagons, container wagons and other freight wagons. The functionality of DAC was tested under real operating conditions.

Test phase III was the acid test for the train’s completely redesigned electrical equipment, an outcome of the previous test runs. The upgrade from 110 volt direct current to 400 volt alternating current is intended to enable additional digital applications such as freight monitoring and automation functions. The technical refinements which manufacturers Voith and Dellner had made to the couplers were also put to the test. At the end of test phase III, the DAC consortium decided in favour of the Scharfenberg or latch-type coupler system. “With prototypes for DAC electrical components, the specifications for the power and data connections in freight trains could also be finalised and the functionalities could be tested,” explains Larissa Rohr, spokeswoman for Deutsche Bahn AG, and she comments on the next steps, “Now electrical systems which are as close as possible to series production components should also be integrated into the demonstrator train. This will allow the electric contact couplings, the control units for coupling and uncoupling actuators, the systems for monitoring train completeness and other electrical components and systems to prove their sturdiness.” Christian Radewagen, Senior Vice President Cargo Rail at Voith Turbo, explains, “DAC4EU is a mandatory platform to gain experience with real-life tests and thus convince the sector and policy makers with robust and reliable products.” In the remaining months of the project, Voith will focus on testing its couplers under real operating conditions. Dellner Couplers was acquired by Wabtec in March 2025.

Conversion from 2028

“After intensive research, development and testing, we are getting closer and closer to series production. Now is the time to establish the innovative idea on the market with products ready for series production. After all, DAC is a key component in making rail travel more punctual, reliable and profitable,” emphasises Dr Daniela Gerd tom Markotten, Member of the Management Board for Digitalization and Technology at Deutsche Bahn AG.

Dr Sigrid Nikutta, Member of the Management Board for Freight Transport at Deutsche Bahn AG and CEO of DB Cargo AG, emphasises, “DAC and the associated digitalisation of rail freight transport will enable new, attractive and economical logistics services for our customers throughout Europe - climate-neutral from door to door, from factory gate to factory gate.”

From 2026, up to 100 pioneer trains with series production-ready DACs are planned to roll throughout Europe - a decisive step on the way to the complete conversion of up to 500,000 freight wagons from 2028. DAC should not only make rail freight transport faster and more efficient, but it is also due to enable new business models and make an important contribution to the efficiency, competitiveness and sustainability of rail freight transport and thus to the transport transition.