Tensorex Sense is an advanced digital monitoring solution developed by Mosdorfer Rail to enhance the performance, safety, and reliability of overhead line tensioning systems. Designed as a retrofit upgrade for existing Tensorex C+ units, the system transforms conventional mechanical tensioning devices into intelligent, connected assets capable of real-time condition monitoring and predictive maintenance support.
Engineered with a “fit and forget” philosophy, Tensorex Sense enables infrastructure owners and maintainers to modernise existing installations without the need for extensive modification or replacement of core equipment. The solution integrates a
combination of rotary transducers, ambient temperature sensors, GSM communications technology, and cloud-based analytics to continuously monitor the operational condition and positional behaviour of the Tensorex C+ unit.
Through its connected digital platform, maintainers gain instant access to live operational data from any smartphone, tablet, or PC.
The intuitive dashboard provides clear visibility of:
- Device location
- Real-time position relative to temperature
- Ambient temperature conditions
- Battery voltage and system health
- Historical performance trends and operating behaviour
This continuous stream of data allows maintainers to remotely assess asset condition and identify anomalies before they develop into operational issues.
A key advantage of Tensorex Sense is its intelligent alerting capability. Should the Tensorex C+ unit approach or exceed predefined operational thresholds, automatic notifications are immediately issued via email and/or SMS text message. These warning parameters are fully configurable during installation, allowing infrastructure managers to tailor alarm limits to specific route conditions and operational requirements.
By delivering early warning of abnormal movement, excessive displacement, or environmental influences, Tensorex Sense supports a proactive maintenance strategy rather than reactive fault response. This significantly reduces the risk of unexpected failures, service disruption, and costly emergency interventions.
Tensorex Sense ultimately improves network safety, reliability, and asset availability by enabling targeted on-track inspections only when required. Maintenance teams can prioritise interventions based on real operational data, improving efficiency while
reducing unnecessary site visits and possession time.
The result is a smarter, data-driven approach to overhead line asset management — extending equipment life, improving operational confidence, and supporting the transition toward digitally connected railway infrastructure
Interested? Check out our website www.mosdorfer-rail.com where you can enquire about all things railway electrification and what we have to offer you.
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This article was originally written by Mosdorfer Rail.
