BNSF leads rail industry in innovation with more patents than all other Class I railroads combined
By EUNICE ARCHILA
Staff Writer
Innovation is part of our DNA. Across the BNSF network, continuous improvement is how we stay on track. From the way we inspect our rails to how we assemble trains, our teams are developing and deploying patented technologies that make our operations safer, faster and more efficient. BNSF has obtained more patents than all other Class I railroads combined.
Here’s how four recent patents are helping us lead the way.
Locating containers
At our Alliance Intermodal facility in Fort Worth, Texas, drones are transforming how we manage inventory. Our patented drone-based Automated Yard Check (AYC) system uses aerial footage and machine learning to triangulate the exact location of containers in 3D space.
“Before this, it took an entire shift to complete a yard inventory,” said Michael Ibanez, co-inventor and manager of technology services. “Now, we maintain a real-time inventory using drones and truck-mounted cameras. That means faster turnarounds for drivers and better service for our customers.”
The system is already in use at Alliance and in Los Angeles, with plans to expand to most of our 27 intermodal facilities by 2027.
Planning intermodal service is a team relay race. Our patent-pending Transportation Service Design system known as Load Plan Optimization (LPO) uses AI to optimize how we assign shipments to trains and routes.
By using an AI-based algorithm that creates a load plan for an outbound train in seconds, we ensure the right containers and trailers are located where they need to be on the production tracks, minimizing the overall distance our hostler drivers need to travel.
“These two patent applications, LPO and AYC, supplement each other,” said Hernandez. “These technologies improve the customer experience and increases efficiency.”
Making engine maintenance simpler
Every five-minute job is a frozen or broken bolt away from becoming hours not minutes. Locomotive maintenance is a specialized discipline that requires extensive training, practical experience, and patience to develop proficiency. The process of changing injectors used to involve awkward angles and a fair amount of physical strain. But a new patented tool, developed by machinists Chad Sellman, Jason Carlson and James Rumpca, at BNSF’s Northtown Diesel Shop in Minneapolis is changing that.
The Engine Component Removal Tool allows mechanics to remove both the injector and its retaining bolt in a single, fluid motion. It eliminates the need for excessive force, reduces the risk of injury and speeds up the job.
“This tool mitigates the chance of line of fire, release of energy and overexertion,” said Sellman, one of the co-inventors. “Now, the tool does the heavy lifting. It’s safer, more efficient, and just makes sense.”
Jason Carlson, who helped spark the idea during a routine injector change, reflected on the journey.
“I’m excited and proud that we recently received a patent for a tool we designed together. We discovered this idea by accident while changing injectors. Through collaboration and multiple iterations, we developed the final version that earned this patent. I never thought I would be receiving a patent, and I’m thrilled to have reached this milestone.”
This achievement reflects our teamwork, creativity, and commitment to making our work more efficient and safer. I’m grateful to be part of a team that turns ideas into reality and can’t wait to see what we create next.”
The tool is now in use in Northtown and is being evaluated for broader deployment to all BNSF’s shops. It’s an example of how innovation at BNSF often starts with solving a problem and a team determined to make things better.
Streamlining switching operations
Switching operations are complex, but our patented Multi-Objective Train Block Assignment System makes them smarter. This technology uses data and optimization models to assign train blocks (groups of cars) to classification tracks in the most efficient way possible.
Whether the yard is full or flowing, the system adapts, minimizing unassigned volume, reducing switch moves, and improving throughput. It even generates visual tools like charts and diagrams to support real-time decision-making.
“What’s exciting is how this started as a manual process on a whiteboard and evolved into a fully data-driven decision assist tool,” said General Director of Transportation Cory Misiewicz. “Now, we’re helping yards optimize hump yard bowl capacity, reduce dwell (time trains are spent in yards), and deliver a product our customers can rely on.”
At BNSF, we’re not just solving today’s challenges, we’re building tomorrow’s railroad. These patented technologies reflect our commitment to innovation, service, and safety.
