In grain stations and ports, railcar axle movers push railway cars so that train engines are not needed. A railcar wheel monitoring system detects the railcar wheels and triggers an axle pushing arm to activate, pushing the railcar to the next loading or unloading station.

Train car distribution centers are subject to high traffic volumes, extreme temperatures, dirty environments, and high vibration, restricting the use of  running cables. Previous solutions involved long-range photoelectric sensors installed in locations where power was available. Because this was often a long distance from the rail car, sensor accuracy was affected by weather and other environmental conditions.

Banner Engineering's SureCross FlexPower Node connected to a limit switch makes operating this system more reliable because eliminates the need for wiring runs. The system also resists vibration, dirty and high-temperature environments.


  • Resists vibration, dirty and high-temperature environments.
  • Eliminates the need to run cables where they would be impractical or not possible.
  • Combines long-distance coverage with ease of deployment, set up and use.

  • Monitoring Railcars Wirelessly with Banner's Performance Series Gateways and Nodes

The railcar wheel triggers a trip arm, activating the limit switch connected to the FlexPower Node. The pusher arm rises and pushes the railcar to the next loading or unloading station.

Banner's enhanced Gateways and Nodes offer increased range in the 900 MHz frequency band. The system density I/O capacity provides up to 12 discrete inputs or outputs or a mix of discrete and analog I/O. 

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