Design and Simulation of Automated Pod Handling for Modular Rail-Based Transport Systems

Background: Modular and autonomous rail-based transport concepts promise increased flexibility and efficiency, but their feasibility strongly depends on reliable and scalable terminal handling operations. In such systems, transport units must be safely and rapidly coupled to carrier units without manual intervention. Methods: This study presents a structured pod-handling concept for a modular rail transport system, covering transport unit preparation, crane-based lifting and positioning, mechanical coupling via twist-lock interfaces, and automated electrical and media connections. To evaluate operational performance, a discrete-event simulation model was developed in AnyLogic that represents the complete loading process from order reception to pod dispatch. Results: Simulation results show that a single crane is sufficient under low-demand conditions, maintaining an average processing time of approximately 12 min per order. As demand increases, system performance becomes highly sensitive to crane availability; insufficient resources lead to excessive waiting times. For high-frequency demand, scalable crane allocation is required to preserve stable throughput. Conclusions: The results confirm that automated pod-handling mechanisms, combined with demand-adaptive terminal resources, are essential for the viability of modular rail pod systems. The proposed process model and simulation framework guide terminal design and support the integration of decentralised rail pods into future multimodal mobility and logistics networks.