At CEATEC 2026 in Japan, Hitachi demonstrated how a small vibration sensor installed beneath a train carriage can help railway operators detect mechanical problems before they cause breakdowns. The technology is part of HMAX for Rail, Hitachi’s AI-powered maintenance platform designed to improve reliability, reduce maintenance costs, and potentially prevent service disruptions.
Last year at CEATEC 2025, we explored Hitachi’s AI agents, conversational industrial machines, and sensor gloves designed to assist factory workers. This year, the company demonstrated how similar data-driven technologies can help engineers maintain trains and subway systems.
We visited the Hitachi booth at CEATEC 2026 and spoke with a company representative, who explained how the technology works and shared examples of railway operators already using it.
How a Vibration Sensor Can Detect Train Problems
Hitachi displayed a compact black sensor labeled Perpetuum Onboard, alongside a video showing its application beneath a train.
The device is designed to attach to the bogie, the mechanical structure beneath a railway carriage that supports the wheels, axles, and suspension system.
When a train moves, its mechanical components generate vibrations. These vibrations change as parts wear out or develop defects. By continuously monitoring vibration patterns, the sensor can help identify unusual behavior that may indicate a developing mechanical problem.
The representative explained that the system compares normal vibration signatures with abnormal ones to detect potential problems early.
The underlying concept is relatively simple, but its implications for railway maintenance are significant.
From Scheduled Maintenance to Condition-Based Maintenance
Traditionally, railway operators perform many maintenance procedures at predetermined intervals, based on time or mileage. This approach helps maintain safety but can also require taking trains out of service even when their components remain in good condition.
Condition-based maintenance takes a different approach: instead of relying exclusively on fixed schedules, operators use sensor data to evaluate equipment condition and determine when intervention is necessary.
With HMAX for Rail, vibration information can be combined with other operational data, including track conditions, signaling systems, and train performance.
Hitachi uses AI and analytics to help maintenance teams identify abnormalities and prioritize inspections or repairs.
The objective is not to eliminate maintenance, but to perform it more efficiently, potentially extending component lifespans while reducing unexpected failures.
Great Western Railway Reports Significant Maintenance Improvements
Poster shown at the Hitachi booth at CEATEC 2026, translated into English.
One of the most compelling examples presented at the booth involved Great Western Railway (GWR) in the United Kingdom.
Hitachi displayed operational results from its condition-monitoring technology deployed on GWR’s Class 800 and 802 trains.
According to the company’s presentation, the system contributed to:
| Reported improvement | Result |
| Reduced bogie-overhaul downtime | 50% |
| Increased operational efficiency | 47% |
| Reduced routine maintenance work | 37% |
| Reduced maintenance materials inventory | 26% |
Hitachi also reported a cumulative gain of 481 days of train availability annually across the monitored operation.
These are company-reported results, but they illustrate the potential economic benefits of detecting deterioration early instead of relying entirely on scheduled maintenance procedures.
Copenhagen Metro: Monitoring More Than Just Trains
Poster shown at the Hitachi booth at CEATEC 2026, translated into English.
Hitachi also highlighted its work with the Copenhagen Metro in Denmark, where HMAX integrates monitoring information from trains, tracks, railway switches, and signaling infrastructure.
The Copenhagen Metro operates automated trains around the clock and reports punctuality exceeding 99%.
During our conversation, the Hitachi representative clarified that this performance depends on the broader railway operation and monitoring systems, not just the vibration sensors.
The company is using HMAX to support the transition toward condition-based maintenance across multiple parts of the metro network, with the aim of improving maintenance efficiency while preserving high service reliability.
HMAX Expands Worldwide
Although the sensor technology itself is not new, Hitachi is expanding its deployment and integrating it into a broader digital railway platform.
In September 2026, the company announced its Enhanced by HMAX initiative, confirming that approximately 2,500 trains already use HMAX sensor technology, with existing orders expected to increase that number to nearly 3,500.
Starting in 2027, Hitachi plans to equip all newly manufactured rolling stock with HMAX sensors, including its ETR1000 high-speed trains.
For passengers, the technology will largely remain invisible. However, if railway operators can detect deteriorating components before they fail, the benefits could be fewer unexpected breakdowns, reduced maintenance downtime, and more reliable train services.
At CEATEC 2026, Hitachi demonstrated at booth 7H010 in Hall 7 how relatively small sensors, combined with sophisticated data analysis, could make a meaningful difference to railway operations worldwide.
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