Mosdorfer Rail has successfully completed the installation of a Tensorex Sense monitoring unit on the Sheffield Supertram network, marking an important milestone in the development of intelligent monitoring for railway overhead line infrastructure.

Tensorex Sense Side View
Close-up view of the Tensorex Sense monitoring unit and solar panel fitted to the mast alongside the Tensorex C+ tensioning device, showing the compact, low-impact nature of the installation.

The installation, completed on 22 June, demonstrated the simplicity and speed with which Tensorex Sense can be integrated into existing infrastructure. With an installation time of under one hour, the unit was quickly fitted, configured and brought online, providing immediate access to remote monitoring capabilities.

Tensorex Sense is a next-generation monitoring solution designed to transform conventional overhead line tensioning systems into intelligent, connected assets. By enhancing the proven Tensorex C+ spring tensioning device, the system enables operators to gain greater visibility of their infrastructure without the need for significant modifications or disruption to existing assets.

Tensorex C+
A pair of Tensorex C+ spring tensioning devices mounted on the overhead line mast, showing the tensioning dial faces used to monitor contact wire regulation length.

Key benefits of Tensorex Sense include:

  • Real-time condition monitoring
  • Predictive maintenance capabilities
  • Remote asset visibility
  • User-defined alerts delivered directly to devices
  • Improved network reliability
  • Maintenance-free monitoring technology
  • Data-driven asset management

The successful Sheffield installation demonstrates how digital monitoring technology can be deployed rapidly and with minimal disruption, while providing operators with valuable information about the condition and performance of critical overhead line equipment. By moving towards condition-based and predictive maintenance, operators can make more informed decisions, potentially identify developing issues earlier and optimise maintenance planning.

Tensorex Sense Dashboard
The Tensorex Sense web dashboard, accessed on-site via a mobile device, displaying real-time data from Site HAL3591 including unit type, mounting position, current tension reading, temperature and battery voltage.

The installation also provided an opportunity to demonstrate the system’s ability to operate in demanding environmental conditions. With temperatures in Sheffield reaching exceptionally high levels in the period surrounding the installation, the project highlighted the importance of resilient railway equipment capable of performing reliably as infrastructure faces increasingly challenging weather conditions.

Tensorex Sense with Tram
The fully installed Tensorex Sense unit mounted on an overhead line mast at Halfway Park & Ride, with a Supertram vehicle approaching in the background — demonstrating the system operating live on the network.

Mosdorfer Rail would like to thank Supertram for its support throughout the installation and everyone involved in delivering this important project.

The Sheffield installation represents an exciting first step towards bringing intelligent tensioning system monitoring to railway networks worldwide, supporting the continued digitalisation, reliability and efficiency of rail infrastructure.

This article was originally published by Mosdorfer Rail.

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