Overview

As railway networks expand and modernize, the demand for precision in assembly and fabrication has never been higher. Minor defects in alignment, installation, or construction can escalate into operational disruptions or critical safety risks.

NorrStudio, built by NorrSpect, delivers AI-powered visual inspection to identify fabrication anomalies and assembly faults in real time—preventing errors before they become systemic problems in rail and infrastructure projects.

About NorrSpect

NorrSpect is a Swedish AI innovation company based in Umeå, known for pioneering AI visual inspection platforms for leading production companies such as Volvo Cars. With deep experience in high-stakes, precision manufacturing, NorrSpect brings its advanced AI toolkit to the railway and infrastructure sectors—transforming manual inspection into intelligent, real-time assurance.

The Challenge: Hidden Faults in Field Assembly

Railway infrastructure involves complex, multi-phase assembly—from track laying to tunnel construction to signal integration. Errors like joint misalignment or faulty overhead wire tension may not be caught until after commissioning, when the cost of correction is dramatically higher.

Common issues include:

• Misaligned rail joints causing track irregularities or speed limitations

• Missing or incorrect track fasteners compromising stability

• Improper installation of signaling components leading to malfunctions

• Uneven slab track causing vibration and structural degradation

• Tunnel assembly defects like segmentation gaps affecting structural integrity

Common Assembly & Fabrication Defects Identified

• Rail misalignment at joints resulting in dynamic stress or wear

• Missing or loosely installed fasteners along rail segments

• Signal light installation errors, such as misdirection or improper mount angle

• Improper overhead wire tension, risking power fluctuation or line break

• Uneven slab track height that disrupts train balance or leads to track deformation

• Tunnel wall segmentation gaps allowing water ingress or instability

NorrStudio in Action: Intelligent Oversight in the Field

NorrStudio leverages high-resolution cameras, deep learning models, and edge-based inference to monitor and validate rail assembly tasks on-site. The platform detects deviations in real-time, highlights anomalies, and assists crews in correcting errors immediately—without interrupting work cycles.

System Capabilities:

• Joint-level rail alignment analysis using 3D surface matching

• Fastener presence and torque position verification

• Visual and geometric validation of signal light orientation and placement

• Real-time detection of slack or overstretched catenary wires

• Height mapping and tilt detection on slab track modules

• High-contrast detection of segmentation gaps in tunnel interiors

Deployment Highlight: Aligning Rails with Micron-Level Precision

Problem:

A metro contractor faced recurring alignment issues during track laying, leading to rework and safety concerns during certification.

Solution:

NorrStudio was deployed with drone-mounted and track-side vision systems. The software continuously monitored each rail joint during installation, comparing position, gap, and tilt against digital plans.

Result:

• 94% reduction in post-installation rework

• Accelerated alignment verification by 3x

• Improved worker safety by reducing manual inspection exposure

• Full compliance with UIC and EN railway installation standards

Quantifiable Results

Why Rail Builders Choose NorrStudio

• Increases speed and accuracy of field assembly inspections

• Catches errors as they happen—reducing downstream delays

• Tailored to the specific geometry and tolerance of railway components

• Integrates seamlessly with BIM, GPS, and ERP platforms

• Operates in harsh environments (tunnels, outdoor yards, high dust)