Catenary Wire Wear Measuring System (CatPro)

What Is a Catenary Wire Wear Measuring System?

The Catenary Wire Wear Measuring System, also known as CatPro, is an advanced railway monitoring tool designed to detect wear in overhead contact wires. Over time, as pantographs repeatedly glide along these wires to draw current, the contact area begins to erode. This wear can compromise electrical performance, introduce safety hazards, and escalate maintenance costs if left undetected.

CatPro solves this challenge by using a non-contact laser triangulation system combined with high-resolution cameras mounted directly on the pantograph. This setup enables continuous, automated overhead wire wear inspection without interrupting train operations or requiring manual intervention on the track.

Why Is Overhead Line Wear Measurement Important?

In electrified rail systems, the integrity of overhead lines is mission-critical. These wires must maintain precise contact with pantographs to provide consistent electrical power to trains. As they degrade due to friction, wear, weather exposure, and vibration, several issues can arise:

• Voltage instability
• Reduced current collection efficiency
• Overhead wire breakage
• Increased carbon buildup on pantographs

Operators can proactively plan maintenance and avoid unplanned service interruptions by investing in reliable overhead contact wire wear monitoring.

How Does CatPro Work?

The CatPro system integrates:

• Laser triangulation sensors to calculate the exact wire diameter
• High-resolution cameras for visual inspection and documentation
• Real-time processing software to log and interpret data

It mounts directly to the pantograph head and operates seamlessly while the train is in motion, making it ideal for integration with scheduled services or inspection vehicles.

CatPro is capable of detecting minute reductions in wire diameter, enabling timely corrective action and data-driven lifecycle extension strategies for the catenary infrastructure.

Key Features of CatPro

✅ Contactless Operation: Measures wear while in service—no disruption required.

✅ High Accuracy: Detects micrometer-scale variations in wire thickness.

✅ Dual Wire Capability: Supports both single and twin contact wire systems.

✅ Automatic Data Logging: Stores diameter and wear data for every measured segment.

✅ Real-Time Monitoring: Continuous data flow with camera-based confirmation.

✅ Pantograph-Mounted: Utilizes existing pantograph infrastructure for deployment.

✅ Integration Friendly: Can work alongside the OVHWizard and other diagnostic systems.

Applications and Use Cases

CatPro is designed to serve railway operators, infrastructure maintainers, and asset managers responsible for:

• Urban transit systems (metro, tram, and light rail)
• High-speed intercity rail networks
• Regional and suburban electric lines
• Electrified freight corridors

The system is especially useful in environments where:

• Contact wires experience accelerated wear due to frequent service
• Manual inspections are too risky or logistically complex
• Continuous monitoring is necessary due to high network load

CatPro has been adopted by leading railway operators in Germany, the Netherlands, Switzerland, and the UK, and continues to expand across other electrified rail systems globally.

Integration with the OVHWizard

CatPro is fully compatible with the OVHWizard—another flagship product that measures catenary height and stagger. When paired, these two systems form a complete overhead line monitoring suite:

• OVHWizard covers vertical and lateral geometry

• CatPro handles wear measurement and wire profiling

Together, they provide a complete view of the overhead contact system’s health, enabling predictive maintenance, real-time alerts, and trend analysis over time.

Benefits for Infrastructure Operators

By using CatPro, rail operators can:

• Prevent costly emergency maintenance

• Minimize service disruptions caused by unexpected wire failures

• Extend the life of overhead contact systems through early intervention

• Plan renewals with data-driven insights

• Reduce manual labor and track occupation time

• Ensure compliance with safety regulations and asset health standards