Track Inspection Vehicle - Segula

Client

SEGULA

Locations

Melbourne, Australia

Core Capabilities

Software engineering
PLC design and development
Testing and commissioning

Technologies

CODESYS development environment (SIL 2 compliant)

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Project Summary

Segula Australia has been awarded a design and build contract to integrate the AOS Signalling System onto a Track Inspection Vehicle. Segula Australia’s scope covers the mechanical, electrical and software development and integration.

Synertec is responsible for the software development activities within this wider project. Track Inspection Vehicle inspects railroad track and roadbed for surface wear, alignment, curvature, elevation, drainage stability, and related conditions to determine conformance to established track safety standards; detects violations of standards and takes remedial action. The system needs to adhere to SIL 2 safety standard.

The Challenge

Synertec has been engaged to perform all work including the software, development, integration, testing and commissioning.

The key deliverables include:

Completion of PLC software designs to support the AOS interface requirements (including concept design, proof of concept and detailed design) and meet EN50128 requirements.
Verification of the PLC software through Engineering test
Support Segula Technologies with completing a SIL2
assessment and documentation.
Co-developing architecture and design document.
Validating source code through CODESYS SIL 2 Checklist and Source Code Validation report.
On-site vehicle and controller integration testing.

Synertec's Solution

Synertec delivered the complete software development, verification and commissioning scope for the AOS signalling system integration on Segula’s Track Inspection Vehicle. The team engineered a SIL 2‑compliant PLC application using CODESYS, incorporating safety logic, alarm management, system diagnostics and seamless operator interfacing. The controller was designed to communicate with the vehicle’s ECU via the J1939 protocol, enabling safe and reliable control of all mechanical, hydraulic and electrical subsystems.

Working collaboratively with Segula Technologies, Synertec co‑developed the system architecture and design documentation while supporting the SIL 2 assessment process. Verification activities included engineering tests, detailed software validation, and completion of all required CODESYS SIL 2 checklists and reports. On‑site integration testing ensured that the software functioned correctly within the Track Inspection Vehicle environment.

Through an agile delivery approach and deep expertise in safety‑critical automation, Synertec provided a certified, robust and fully integrated control solution that meets EN50128 and SIL 2 safety requirements.