Reverse Engineering Helps Overcome Obsolescence in UK Rail Power Components

Application

Railway infrastructure | Power conditioning and magnetic components | Obsolescence mitigation

Products Used

Rail chokes, inductors and bespoke magnetic components – REO Rail Solutions

Background

Railway systems are designed for very long service lives, often exceeding 30 years. Over time, original components can become obsolete as manufacturers discontinue products or exit the market, creating challenges for operators maintaining ageing fleets and infrastructure.

In the UK rail industry, magnetic components such as chokes, inductors and transformers are particularly affected, despite remaining critical to safe and reliable operation.

REO has supported the rail industry for decades, including the acquisition of the Nieke brand and product line over 20 years ago. Nieke products remain widely recognised within railway engineering circles, and this legacy continues to inform REO’s approach to rail-qualified magnetic components and reverse-engineering support today.

The Challenge: Obsolescence and Continuity of Supply

When components become obsolete, spare availability diminishes, and costs rise. In many cases, original drawings or technical data are unavailable, making direct replacement difficult. Without an effective strategy, critical systems may be exposed to increased downtime or risk.

Reverse Engineering as a Solution

Reverse engineering allows obsolete components to be recreated by analysing exisitng parts to determine their electrical, mechanical and thermal characteristics. This enables the manufacture of accurate form-and-function replacements, often incorporating modern materials and improved performance.

The REO Approach

REO applies a structured reverse-engineering methodology that includes physical analysis, electrical characterisation under load, and the use of modern materials and manufacturing techniques. This approach enables the production of replacement components that meet current rail safety and performance standards while maintaining compatibility with existing systems.

Results & Benefits

• Reduced risk from component obsolescence
• Continued operational reliability of rail systems
• Improved long-term performance and service life

According to REO’s engineering team, reverse engineering provides a practical route to sustaining legacy rail systems without major redesign.

Engineering Support for Rail Applications

REO UK supports rail operators, integrators and manufactur