Case Study: AMP Rail LLC
As a rail fleets move from legacy lead-acid to lithium-ion starter batteries, AMP Rail needed more than a hardware upgrade – it needed proof. This case study shows how ODOS enabled real-time, high-resolution monitoring of lithium-ion systems under extreme conditions, helping AMP Rail validate safety, extend battery life, and shift industry perception. With zero critical failures across -40°C to +50°C and a 5–10 year acceleration in adoption timelines, the collaboration offers a blueprint for how data-driven engineering can de-risk innovation in conservative, safety-critical sectors.
Background
The rail industry is undergoing a significant transition from traditional lead-acid batteries to advanced lithium-ion alternatives. This shift is driven by the urgent need for cleaner, more efficient, and reliable energy sources in locomotive power systems. For decades, lead-acid batteries have been the standard across the sector, used to start diesel engines and power auxiliary systems, but they are increasingly being outpaced by lithium-ion technologies, which offer higher energy density, longer cycle life, and reduced maintenance.
AMP Rail, a leader in lithium-ion power systems for locomotives and heavy industrial equipment with a specific focus on starter battery solutions, is at the forefront of this transition. Rather than simply replacing one technology with another, AMP Rail is helping guide its partners through the complexities of adopting lithium-ion batteries in real-world rail environments.
To succeed in this role, AMP Rail required a solution that could provide deep operational visibility into battery performance, particularly under the kinds of extreme and variable conditions that rail fleets routinely face. Real-time, accurate data would be essential for validating safety, managing performance, and overcoming the industry’s long-standing hesitation around lithium-ion adoption. Recognising the central role of data in this transition, AMP Rail turned to ODOS for their expertise in embedded vehicle data systems and cloud-based analytics.
Key Challenges:
The shift to lithium-ion battery systems brought with it a range of technical and operational challenges. Safety remained a top concern, with persistent fears around overheating, thermal runaway, and potential fire risks continuing to affect industry confidence. In parallel, batteries needed to deliver reliable performance across a wide range of environments – from freezing Arctic conditions to desert heat exceeding 50°C.
In addition to safety and environmental performance, AMP Rail faced the challenge of integrating these new technologies within a landscape built around lead-acid systems. Maintenance teams were trained and equipped for legacy platforms and lacked the tools and data required for predictive diagnostics and proactive decision-making. This contributed to inefficient maintenance cycles, unnecessary battery replacements, and increased operational costs driven by reactive fault management and avoidable downtime.
AMP Rail’s role wasn’t just to engineer high-performance battery systems; it was also to help its partners adapt. That required not only technology but also transparency. To build trust in lithium-ion as a safe and scalable solution, AMP Rail needed the ability to monitor performance, detect early signs of failure, and validate resilience across operating environments. That’s why capturing and interpreting data became so critical – and why they partnered with ODOS.
Approach:
ODOS deployed its advanced monitoring and analytics platform to give AMP Rail real-time visibility into the performance of their lithium-ion battery systems. Smart sensors and robust data loggers were embedded directly into each battery unit, capturing critical metrics such as voltage, charge cycles, temperature, current draw, and long-term degradation patterns.
These insights allowed operators and engineers to:
- Detect early warning signs of battery failure, well before safety thresholds were crossed
- Validate safe, stable performance under extreme temperature and environmental stress
- Automate diagnostics and reduce the need for manual inspections
- Build a rich data record to support safety certification and regulatory compliance
The ability to monitor in real time was especially vital for mitigating risks like thermal runaway where internal battery conditions can quickly escalate into dangerous overheating. Drawing parallels with the automotive sector, where high-end British sports car manufacturers monitor vehicle parameters in real time before approving testing, ODOS brought similar standards of scrutiny and safety assurance to the rail industry.
Implementation
The initiative began with a structured pilot, co-developed by ODOS and AMP Rail’s technical teams. A test fleet was fitted with sensors and data loggers, with data streamed to ODOS’s secure, cloud-based platform for analysis and monitoring.
Engineers accessed a centralised dashboard that offered live views, performance alerts, and historical trend analysis aligned to AMP Rail’s specific operational protocols. Custom configuration was a major success factor – the platform’s notifications and reporting tools were tailored to existing maintenance workflows, minimising disruption and requiring minimal training for engineers, drivers, and depot teams.
Following the successful pilot, including stress-testing in demanding environmental conditions, the solution was scaled up across additional fleets and is now fully integrated into AMP Rail’s predictive maintenance and safety processes.
Results And Impact
Quantitative outcomes:
- Dramatic reduction in diagnostic time for battery-related faults
- Significant fuel savings due to reduced engine idling and smarter charge management
- Battery life extended through predictive maintenance
- Zero critical failures in extreme temperatures from -40°C to +50°C during the trial period
- Accelerated lithium-ion adoption across multiple industry partners by an estimated 5 – 10 years
Qualitative benefits:
- A data-rich environment for decision-making, reducing reliance on assumption-based diagnostics
- A shift in industry perception from viewing lithium-ion as risky to seeing it as proven and future-ready
- A competitive edge positioning AMP Rail as leaders in green rail innovation
- Increased confidence and satisfaction amongst engineers thanks to faster fault resolution and fewer system breakdowns
Client Testimonial
“The more data we have, the more confident the industry becomes in making the transition to lithium-ion. ODOS has been instrumental in giving us and our customers confidence. The system has removed the guesswork and we’re already seeing the impact in reduced downtime and higher operational reliability.”
David Eldridge, AMP Rail
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