COTS-arkiv - Prover - Engineering a Safer World

COTS – A key enabler of open signaling

Sara Månsson — Wed, 10 Dec 2025 11:50:00 +0000

From closed systems to open standards

Across the railway industry, many infrastructure managers are still operating relay-based signaling systems. They work – but maintaining them is costly, spare parts are disappearing, and the expertise required to service them is becoming harder to find. At the same time, demands for higher capacity, improved safety, and faster modernization are growing. Increasing train traffic, automation initiatives, and stricter safety standards are accelerating this transformation.

To move forward, the industry needs to shift from proprietary, vendor-specific systems to open and standardized architectures. This is the foundation of open signaling – which promotes interoperability and vendor independence for the next generation of railway signaling systems. At the heart of this transformation lies COTS – Commercial Off-The-Shelf components.

What COTS means for railway signaling

COTS refers to standard, industrial components – such as PLCs or I/O systems – that are already available on the market. The term originates from the software industry and refers to ready-made, industrial solutions that can be integrated with minimal customization. Unlike proprietary hardware developed for a single supplier’s platform, COTS enables signaling systems to be built on open, accessible technology.

For the railway sector, this brings several advantages:

Flexibility: Hardware can be replaced or upgraded without redesigning the entire system.
Vendor independence: Infrastructure managers are no longer locked into one supplier.
Cost efficiency: Using standard components reduces lifecycle and procurement costs.
Scalability: Systems can be deployed and adapted more easily across networks.

But more importantly, COTS is not just about cost or convenience – it’s what makes open signaling technically and commercially possible.

Prover’s role – safety through formal methods

Using COTS in signaling introduces new opportunities, but also new challenges. Especially when it comes to how safety is demonstrated. If signaling hardware becomes open and interchangeable, and the signaling principles are moved to software, then much of the safety validation must move to software too.

Experience from modernization projects shows that using digital twins is an effective way to manage this transition. Digital twins allow infrastructure managers to test, validate, and verify the principles behind new COTS-based systems before deployment – ensuring full safety integrity throughout the process. Prover’s use of formal methods, i.e., mathematical proof-based verification, ensures that safety-critical software behaves exactly as intended, regardless of the underlying hardware platform.

With this approach, operators can safely adopt COTS-based systems while maintaining the same rigorous safety assurance as in traditional, proprietary systems.

Migration: from relay to open architecture

For many infrastructure managers, the journey starts with migration. Moving from aging relay-based systems to COTS-based platforms is often the first practical step toward open signaling.

A concrete example is the Stockholm Metro modernization, where Prover and partner Cactus introduced COTS-based PLCs while retaining existing relay interlockings. Using a five-step migration process supported by digital twins, the project achieved a smooth transition to a modernized architecture – reusing proven logic and ensuring safety through formal verification. This approach reduces risk, ensures continuity, and creates a future-proof foundation for digital evolution. Read more about Relay Signaling Migration here.

Open signaling – a shared vision for the industry

Open signaling is not a product; it’s a concept and a way of thinking. By combining open interfaces, standardized hardware (COTS), and formally verified software, the railway industry can build signaling systems that are:

Software-driven, through verified logic
More efficient, through shared standards
More sustainable, through reduced lifecycle complexity

Prover’s contribution to open signaling is to make this vision practical – transforming safety-critical verification into a digital, automated process that supports an open and innovation-driven railway ecosystem. Read about the Open Signaling Initiative here.

Shaping the future of railway signaling

COTS is more than a hardware choice, it’s a catalyst for change in railway signaling modernization. It enables the shift from closed, proprietary systems to open, future-proof architectures where flexibility, safety, and innovation coexist. Together with open signaling principles, COTS paves the way for a modern and future-ready railway infrastructure. And with Prover’s expertise in safety verification and signaling software, the industry can move forward with confidence – building signaling systems that are open, interoperable, and safe by design.

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Launch of the Open Signaling Initiative

Jesper Carlström — Thu, 15 May 2025 15:55:41 +0000

RECORDED WEBINAR

COTS

Recorded on June 11, 2025

The Open Signaling Initiative redefines how rail and metro signaling systems are developed, deployed, and maintained.

Signaling systems are today delivered as closed systems that have made customers dependent on the supplier for decades. When support and maintenance agreements expire, it is not uncommon that the whole system needs to be replaced, at high costs and with long service interruptions. Open signaling changes this paradigm entirely.

Inspired by the modularity and flexibility of earlier relay-based systems, and by open systems in domains such as IT/ICT, open signaling reintroduces freedom and adaptability into modern rail and metro signaling. It promotes open, modular, and interoperable architectures where independent components from different suppliers can seamlessly work together.

Agenda:

Introduction to the Open Signaling Initiative
Key principles for open signaling
Prover's contribution to open signaling
The roles in open signaling projects
How to become a part of the movement and the ecosystem

Yes please, send me the recording!

Speakers

Jesper Carlström
COO and Open Signaling Lead at Prover

Inlägget Launch of the Open Signaling Initiative dök först upp på Prover - Engineering a Safer World.

Relay Signaling Migration: The structured solution for railway signaling modernization

Mats Boman — Wed, 09 Apr 2025 08:12:34 +0000

Transforming legacy systems based on relays into future-ready railway operations

Prover is committed to engineering a safer world by enabling the railway industry to modernize confidently. Building on our expertise in Signaling Design Automation (SDA) and formal methods, we proudly introduce our solution: Relay Signaling Migration – a structured approach for transitioning relay-based interlocking systems to modern platforms based on open signaling.

The urgent need for migration

As legacy systems near the end of their lifecycle, reliable migration is more critical than ever. Relay-based interlocking systems have supported railway operations for decades, but maintaining them presents increasing challenges:

Loss of expertise: The industry faces a growing shortage of relay specialists
Parts scarcity: Essential components are becoming harder to source
Documentation gaps: Critical system knowledge is often incomplete or missing
Rising maintenance costs: Aging systems require more frequent intervention
Compatibility limitations: Integration with modern technologies is restricted
Safety concerns: Meeting current standards becomes increasingly difficult

Without the expertise of those who built these systems, migrating to a modern solution is no longer an option; it’s a necessity.

Why migration efforts often stall

Despite the clear need, many organizations struggle to begin the transition due to the following:

Insufficient legacy system documentation
Complex compliance requirements
Perceived migration complexity
Operational disruption concerns

The Prover solution: A three-step approach

Relay Signaling Migration eliminates these roadblocks by providing a systematic approach rooted in automation and formal verification:

Step 1: Forward engineering of existing systems

Capture system logic through diagram analysis
Create formal specifications of generic functionality
Document critical knowledge in structured formats

Step 2: Create digital twins and apply changes

Replicate legacy systems in digital environments
Test modifications safely before deployment
Validate changes without operational impact

Step 3: Transfer logic to an open platform

Generate or port logic to modern systems
Automate verification and validation
Ensure compliance with current safety standards

Key technologies enabling successful migration

Our solution leverages powerful tools that serve as the Signaling Design Automation platform developed specifically for these challenges:

Prover Extractor: Our advanced tool reads and analyzes circuit diagrams, creating accurate digital twins of existing relay-based systems
Prover Studio: A specialized Integrated Development Environment (IDE) used for modeling and formal specification creation.
Prover iLock is the cornerstone of specific application (SA) development. It provides a robust platform for configuration, simulation, and formal verification. This tool supports data preparation, code generation, and scenario-based simulation, ensuring that requirements are met with precision.
Prover Certifier: Certified for CENELEC EN 50128 and EN 50716 SIL 4 compliance, Prover Certifier automates the creation of safety evidence, ensuring full regulatory adherence. It validates safety properties using formal methods, providing comprehensive, traceable safety documentation essential for railway applications.

The long-term benefits of modern signaling

Migrating to an open signaling system yields numerous advantages:

Operational Efficiency: Real-time diagnostics and predictive maintenance reduce delays and manual labor
Scalability & Adaptability: Open platforms support evolving operational needs and future infrastructure growth
Compliance & Safety: Modern systems meet today’s standards, supporting secure and regulated operations
Cost Control: A phased, verified approach ensures project timelines and budgets stay on track

Your partner for railway transformation

The Prover solution Relay Signaling Migration is your blueprint for a controlled, secure, and future-proof transformation of relay-based interlocking systems. It brings together Prover’s deep expertise in formal verification and SDA to help railway operators meet modernization goals without compromising on safety, cost, or performance.

Whether you’re looking to preserve decades of system knowledge, reduce reliance on obsolete technology, or take the first step toward an open signaling future, Prover is ready to lead the way.

Contact Prover today to begin your structured migration journey.

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How to successfully migrate existing interlocking systems to an Open Signaling solution

Mats Boman — Mon, 10 Mar 2025 11:02:17 +0000

ONDEMAND WEBINAR

COTS

Recorded on April 9, 2025

Overcoming challenges with automation & digital twins

Interlocking systems based on relays and mechanics have reliably powered railway operations for decades, but with expertise disappearing and spare parts becoming scarce, the urgency to modernize is growing. While these systems may remain in use far beyond 2030, the risk of operational disruptions and compatibility challenges is increasing. How can rail operators ensure a smooth and secure transition to modern signaling solutions?

This webinar explores how Signaling Design Automation, digital twins, and formal methods can simplify the migration process in controlled steps. Our experts explain the step-by-step approach to transitioning from relay-based systems to an Open Signaling solution that minimizes risks, reduces costs, and ensures compliance.

Agenda:

Common barriers preventing migration and how to overcome them
Recommendation for how to take your first steps toward migration
How to do a migration in controlled steps enabling an Open Signaling solution
Examples of successful migration projects
Q&A with the experts

Yes please, send me the recording!

Speakers

Mats Boman
VP Business Development at Prover

Benjamin Blanc
Solutions Manager at Prover

Inlägget How to successfully migrate existing interlocking systems to an Open Signaling solution dök först upp på Prover - Engineering a Safer World.

Discover next-level rail engineering: Prover Station, COTS Solutions, and AI at InnoTrans 2024

Amanda Öberg — Mon, 09 Sep 2024 08:04:36 +0000

The demand for safer, more efficient, and reliable signaling systems is at an all-time high. At InnoTrans 2024, Prover is thrilled to present our latest innovations that are poised to transform the future of railway signaling. From the powerful Prover Station platform to the seamless integration of COTS technology and AI-driven automation, our solutions are designed to meet today’s challenges and unlock new opportunities.

Discover Prover Station

Prover Station is a web-based platform specifically designed to meet the rigorous verification and validation needs of the rail and metro signaling industry. With decades of expertise behind it, Prover Station streamlines the creation, management, and verification of formal proof projects while integrating digital twins for comprehensive testing and training.

What Prover Station offers:

Formal verification: Prover Station organizes formal verification tasks into Proof Projects, guiding you from initial specifications to final validation. By identifying and correcting logical errors early, it reduces the risk of costly mistakes. The process is fully customizable to meet your safety and performance standards, ensuring compliance with all regulatory requirements.
Digital twin aggregates: Prover Station enables the creation and management of digital twins, which is essential for real-time system monitoring, analysis, and optimization. It aggregates multiple digital twins into a unified model, providing a comprehensive overview for design, testing, and decision-making.
Integration and flexibility: Whether you prefer a cloud-based or on-premises solution, Prover Station adapts to your needs. It integrates seamlessly with external simulators and hardware via MQTT or OPC-UA protocols, offering flexible web interfaces and automation through APIs.

Prover Station is built to enhance the safety, efficiency, and reliability of signaling systems in the railway and metro sectors. From proof projects to ongoing operations, it provides the essential tools you need for success.

Join us on Wednesday, September 25th, from 12:00 to 14:00, for a live demonstration during our mingle event. See Prover Station in action and connect with our team.

The transformation into open and interoperable signaling solutions via COTS

COTS (Commercial Off-The-Shelf) technology is playing a vital role in the modernization of railway signaling systems. Unlike traditional, custom-built systems that are costly to maintain and difficult to upgrade, COTS offers ready-made solutions that are easier and more affordable to integrate. This flexibility allows for faster deployment and better adaptation to new technologies.

The transition to COTS is crucial for updating outdated signaling systems. With COTS, railway operators can quickly adopt new technologies, reduce reliance on single vendors, and achieve higher safety standards more efficiently.

While challenges such as legacy systems, slow standardization, and integration complexities remain, COTS provides dynamic, cost-effective solutions that simplify management and updates. By adopting COTS, you can reduce costs, accelerate development, improve maintenance, and enhance system reliability—key factors in maintaining the highest safety standards in modern rail systems.

We will demonstrate how Prover’s products seamlessly integrate with COTS systems using a Schneider PLC at our booth. Stop by and see it in action!

Advancing railway signaling with AI

We are pushing the boundaries of railway signaling design automation by integrating AI with Formal Methods and Digital Twins, solidifying our commitment to “Engineering a Safer World”. Current industry practices are outdated, and our approach has already delivered significant improvements in efficiency and automation. By incorporating AI, particularly Large Language Models (LLMs), we aim to make complex tasks like requirements engineering, design, verification, and safety more intuitive and efficient.

At InnoTrans, we will showcase how AI is transforming railway signaling. Engage with our AI tools and discover how our innovations are bringing new levels of automation and safety to the industry. Check out Prover Labs, our space and community where you can try out AI-driven innovation and be part of shaping the future.

Join us at InnoTrans 2024

We will be at booth 130 in hall 3.2 from September 24 to 27. Don’t miss the opportunity to see firsthand how Prover is revolutionizing railway signaling. Want to schedule a meeting? Click here to fill out the form, and we will suggest a time slot.

We look forward to welcoming you to our booth at InnoTrans 2024. See you in Berlin!

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The railway industry is transforming into more interoperable and vendor-independent solutions

Mats Boman — Tue, 03 Sep 2024 10:58:19 +0000

We notice an increasing interest in following other industries in transforming into open and interoperable solutions. This is a transformation from vendor-specific solutions, where software and hardware are integrated, and interfaces to other systems are proprietary, to interoperable solutions, where software and hardware are separated and standardized, simplifying the solutions’ ability to run in the cloud. This opens up for the use of standardized COTS-hardware also in the railway industry.

The current solutions for railway signaling

The backbone of safe and efficient railway operations lies in its signaling systems. Railway signaling systems control train movements, ensuring they travel safely and navigate the rail network without incidents. As trains are a vital component of global infrastructure—both for cargo transport and public transit—the reliance on advanced signaling systems to manage this signaling challenge is crucial.

The existing systems are based on vendor-specific hardware and software solutions that depend on each other from leading vendors.

The challenges with vendor-specific solutions are:

They are not interoperable with other systems
Drives cost for system integration, upgrades, and maintenance
It does not give control to the buyer but rather to the vendor
Will lock in the customer with one vendor

The transformation into open and interoperable solutions via COTS

The market wants to move towards digital and interoperable solutions. The use of COTS software and hardware is an enabler of this. An example of this trend is the initiative driven by Indra and Amey, which was announced in November 2023.

The Prover solution’s foundation is to enable the separation of software and hardware. This is done by providing a software solution for developing Digital Twins of the complete Rail Control System and automating all steps from tendering, development, safety verification, and maintenance.

The software solution runs on any hardware platform, including COTS platforms like:

HIMA
Schneider
Pilz
…

This leads to significant benefits like:

Lower costs and risks using digital twins
Reusability with open and standardized PLC languages, specifications, and interfaces
Customers will gain more control of the solution
Maintainability and interoperability over the life cycle

Signaling projects can be based on developing Digital Twins of the solution even before the tender phase. These digital twins will become the basis for the tender process, software development, testing, safety verification, and maintenance.

Implementation of open signaling solutions with COTS

There are two scenarios:

The need to migrate existing brownfield solutions
The need to effectively develop new greenfield solutions for new rail line projects

The process is divided into three steps:

Create a digital twin of the system
Define and specify the functionality of the new system based on formal methods
Generate code for the specific COTS hardware platform and verify safety

You can find more information here about interoperable COTS-based solutions and how to implement them for railway signaling.

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Prover’s advanced solutions powering Orléans Tramway signaling project

Benjamin Blanc — Wed, 03 Jul 2024 15:13:46 +0000

Prover is proud to announce our integral role in the latest railway signaling project for the Orléans tramway. In Consortium with Fortil Mobility, ETF, SES Signalisation, Prover have secured a turnkey project that will see the adaptation of the existing signaling system to create a new intersection with Avenue Emile Bernon. This endeavor not only marks a significant milestone for our cluster but also underscores the cutting-edge technology and expertise that Prover brings to the table.

Our advanced automation solutions are at the heart of this project, ensuring that every aspect of the signaling system maintains its safety, efficiency, and reliability. Here’s how our products are making a difference:

Comprehensive design and development

Prover’s state-of-the-art software solutions are being utilized to update and validate the automation systems required for this project. Our product Prover iLock ensures that every component of the signaling system meets their requirements. The Schneider PLC code for non-vital logic developed initially with Control Expert has been uploaded to Prover iLock to connect it to the railway layout. In addition, a model of relay vital logic was created from the relay schematics. The combination of these two components, complemented by wayside objects behaviors, provides a working Digital Twin of complete interlocking.

Seamless integration and validation

One of the key challenges in railway signaling projects is ensuring that all systems work seamlessly together. Prover iLock is designed to facilitate smooth integration and rigorous validation processes. With Prover’s expert staff, we performed comprehensive testing and validation, ensuring that the signaling system operated flawlessly from day one. This reduces risks and accelerates the project timeline, with the commissioning scheduled for this summer.

Collaborative success

This project is a perfect example of how collaborative efforts can lead to outstanding results. Prover is proud to work alongside Fortil Mobility, ETF (Vinci group), and SES Signalisation to bring this project to fruition. Each partner brings unique expertise and capabilities, creating a synergy that drives the project forward.

How safe and efficient are your rail control systems? Let’s find out!

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Join Prover at InnoTrans 2024 in Berlin

Amanda Öberg — Tue, 18 Jun 2024 06:59:31 +0000

Prover will be exhibiting at InnoTrans 2024, September 24-27 in Berlin. Visit us at booth 130 in hall 3.2. Our team will be there to discuss our newest advancements and how digital twins and formal methods can help you achieve your rail control projects in less time, at lower cost and with guaranteed safety.

Mingle event on September 25th

Don’t miss our mingle event on Wednesday, September 25th. Join us for a lunch mingle of appetizers and drinks at our booth. We will send out a separate invitation with more information as we get closer to the date.

Launch of Prover Station

During the mingle, we’ll present a live demo of our new solution, Prover Station. Prover Station is an innovative all-encompassing web-based SDA platform, managing digital twins and formal verification.

Develop your rail control solution with COTS products

Explore Prover solutions enabling Open and Interoperable Rail Control Systems with Commercial Off-The-Shelf (COTS) hardware. On display is our integrated development environment for PLCs. We also present a SIL4 solution for migration of relay interlockings to PLCs.

We would like to meet you at InnoTrans

Please click here and fill in the form, and we will get back to you with suggested time slots.

We look forward to welcoming you to our booth 130 in hall 3.2 at InnoTrans 2024. Join us to discuss how Prover can help you achieve your goals. Don’t miss this opportunity to connect with us!

See you in Berlin!

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Create a technology-independent COTS solution for railway signaling

Mats Boman — Mon, 22 Apr 2024 14:18:53 +0000

RECORDED WEBINAR

COTS

Recorded on May 30, 2024

Join us as we explore the transformative potential of Commercial Off-The-Shelf (COTS) PLC solutions in the railway signaling market. This webinar, led by Prover’s experts Mats Boman and Benjamin Blanc, explains how COTS is not just a trend, but a strategic shift towards standardization and enhanced system interoperability. Discover how Prover contributes to this quest for independence, compatibility, and efficiency with COTS technologies. Learn about how to migrate existing interlocking systems.

Agenda:

Discover how COTS drives standardization and compatibility
Strategies for migrating current interlocking systems
Assess COTS compatibility with your future system strategies
Take practical steps toward a COTS-based strategy
Interactive Q&A: Insights from Prover Experts

Yes please, send me the recording!

Hosts

Benjamin Blanc
Solutions Manager, Prover

Mats Boman
VP Business Development, Prover

Inlägget Create a technology-independent COTS solution for railway signaling dök först upp på Prover - Engineering a Safer World.

Case: Developing digital twins for the Stockholm Metro

Gunnar Smith — Mon, 11 Jul 2022 07:56:05 +0000

When the Stockholm Metro set out to upgrade their rail control system, they contacted us at Prover to assist with the transition.

Stockholm Metro’s system consists of a central traffic management system and a relay-based vital and non-vital signaling system distributed over several relay rooms. The plan is to replace the mechanical control panels used by the operators with a modern computerized traffic management system, as well as to replace the non-vital relays with a distributed PLC solution, and, at least for the time being, leave the vital relays intact.

In order to analyze the existing systems and validate this approach, a digital twin of the system was developed using formal methods. These formal methods included formal specifications with an emphasis on the interface, separation of configuration data and generic requirements, automated simulation-based testing, and formal safety verifications.

CLIENT: Stockholm Metro
LOCATION: Stockholm, Sweden
DATE: 2021-2022

Project goals

In this case, the Stockholm metro had three primary goals. The first was to discover any dependencies that would make it difficult to leave the vital relays untouched.The second was to identify any safety critical functions that are dependent on the existing non-vital relay or control panel design, to include such requirements in the specifications for the new systems. For example, physical wiring may prevent certain commands from being received simultaneously, or safety standards and best practices may have changed since the original system was commissioned. And finally, they wished to test out the concept in order to avoid any surprises that could delay the project and make it more expensive.

PROJECT START

At the start of this project, the Stockholm Metro’s architecture consisted of the following components:

Physical maneuver panel – Push/pull buttons and switches for controls, lamps for indications
Non-vital relays – Interface between panel and interlocking, with additional (non-safety related) logic

Vital relays – Safety related signaling logic, locking of routes and points, signal aspects

END GOAL

The end goal of the project was a future architecture consisting of:

A computerized traffic management system with an operator interface
A set of PLCs with the same functionality as the current non-vital relays
The vital relays from the original system left intact, interfacing with the PLCs

The solution in 6 steps

Created a digital twin of existing system
Carried out formal verification of the safety of the current system
Automatically generated the PLC application software
Created a digital twin of the future system
Replaced the model of the PLC with an actual PLC
Replaced the model of the interlocking with the actual relay system

Results

Following this process, the Stockholm Metro was able to successfully validate the modularity of the proposed system and establish that it is feasible to replace the non-vital relays with a PLC system. They were also able to identify a few unexpected details in the existing system.

Furthermore, the digital twin validation approach simplified the transition to the physical environment relay system–testing with the PLC installed in the field was conducted over the course of a single night.

In the future, the Stockholm Metro can use the digital twin for preparing tenders, validation and verification, reproducing issues from field error reports/logs, replacing testing in the field, and training and documentation.

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