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Author: Livia In-Albon

Augmented Reality assisted maintenance

Project tasks

  • Collecting European use cases
  • Providing a report for chosen use cases and a presentation on various customer sites
  • Prototyping of an on-site application
  • Definition of the use cases
  • Initial parametrisation of the Augment Reality inspection system
  • Software localisation
  • Definition of performance parameters
  • Setup of pilot project on site
  • Tuning of the parametrisation of the AR inspection system
  • Training of personnel for prototype application testing
  • Digital O&M prototype usage instructions and application report

Our approach

The project addressed the need to identify, assess, and practically evaluate digital technologies for rolling stock maintenance used in Europe. The objective was to provide transparent insight into proven and emerging digital maintenance solutions for railway vehicles, including trains and rolling stock fleets, based on information available in the public domain.

On top of that, the project aimed to move beyond theory by implementing and validating a selected digital maintenance use case. A virtual reality (VR)-supported maintenance application was chosen and realised at one of the customer’s major production sites to validate feasibility and operational relevance under real industrial conditions.

PROSE conducted a structured survey of European digital maintenance technologies based on industry experience, expert exchanges, and reference projects implemented by railway operators and maintainers. The resulting report focused deliberately on non-patented, legally uncritical use cases to ensure transparency and independence. Based on this assessment, we supported the selection of a suitable digital maintenance application with high practical relevance.

We then realised a VR-supported digital operation and maintenance application directly at the customer’s site. For that purpose, we coordinated a specialised VR technology partner and combined advanced digital tools with our in-depth railway maintenance and engineering expertise. Our independent role and hands-on industry knowledge ensured a solution that was both technically robust and operationally relevant.

Customer benefit

By selecting PROSE, the customer gained access to deep, experience-based insight into European digital maintenance practices beyond pure desk research. The survey provided realistic, industry-proven solutions grounded in actual railway projects and expert discussions.

Through the realisation of a concrete VR maintenance use case, the customer was able to validate digital technologies in practice rather than relying on theoretical concepts. PROSE’s combination of independent consulting, deep railway domain expertise, and the ability to bridge technology providers with operational requirements enabled a reliable and low-risk introduction to digital maintenance innovation, strengthening long-term maintenance efficiency and capability.

 

Train driver cab with diagnostic display screen and control panel inside a FLIRT1 electric multiple unit.

Ensuring long-term availability of FLIRT1 EMUs

Customer: Hessische Landesbahn GmbH, Germany

Project tasks

  • Obsolescence analysis
  • Definition of replacement hardware architecture
  • Software porting to new Compact-PCI platform
  • Linux OS adaptation
  • EMC planning (EN 50121-1)
  • CSM analysis
  • Requirement capture
  • Test specification development
  • Laboratory validation
  • Prototype retrofit support (on-site)
  • Creation of retrofit documentation
  • Support during fleet rollout

Our approach

The FLIRT1 Electric Multiple Units (EMU) operated by Hessische Landesbahn GmbH were equipped with a Compact-PCI diagnostic computer that became obsolete and unavailable on the market.

The diagnostic computer records vehicle events and fault logs while displaying failure messages and troubleshooting guid-ance to the driver. Although the system is not safety-relevant, it is operationally essential for efficient maintenance and fleet availability.

Due to increasing component ageing and an expected rise in hardware failures, the obsolete unit had to be replaced by a successor model with full functional equivalence. The validated vehicle software architecture needed to remain unchanged, in order to classify the measure as maintenance acc. to (EU) 2016/797.

PROSE developed a risk-minimised hardware migration concept that preserved the existing vehicle software architecture.

We replaced the obsolete MEN Compact-PCI computer with a Duagon Compact-PCI successor model and ported the existing application software to the new platform. The Linux operating system environment was adapted to ensure identical system behaviour.

We implemented necessary interface adjustments without changing the validated vehicle software architecture. Our scope included:

  • Porting and validation of the application software
  • Creation of installation images
  • Development of test specification
  • Execution of a Common Safety Method (CSM) analysis
  • Requirement capture documentation
  • Preparation of an Electromagnetic Compatibility (EMC) plan according to EN 50121-1
  • Laboratory validation and on-site prototype verification

We implemented and validated a prototype retrofit as the basis for a seamless fleet-wide rollout. In close collaboration with a specialised software partner, we ensured efficient implementation and full technical traceability.

Customer benefit

Hessische Landesbahn secured the long-term availability of its FLIRT1 fleet without functional changes or impact on the validated vehicle software architecture.

The reuse of the existing installation space reduced retrofit effort and vehicle downtime. The structured CSM process and comprehensive documentation ensured regulatory compliance and full technical traceability.

Through a structured engineering approach and comprehensive documentation, PROSE ensured regulatory compliance, tech-nical traceability and a reliable basis for long-term fleet opera-tion. Our independence from original equipment manufacturers enabled a pragmatic, lifecycle-oriented solution focused on availability and maintainability. A successfully validated prototype forms the basis for the fleet roll-out currently being prepared.

 

      

Driver operating a modern high-speed train cab with digital controls, representing advanced railway systems and certification processes.

Establishing a structured framework for TSI certification and authorisation

Training provided for:

  • TSI certification (NoBo) system for locomotives, passenger rolling stocks and freight wagons
  • NNTR certification (DeBo) and risk assessment (AsBo) systems for locomotives, passenger rolling stocks and freight wagons
  • Risk assessment (AsBo) systems
  • Access process for railway products to the European Union
  • EC certificate system and standard for European Union rolling stock equipment and products

Our approach

The project addressed the need to strengthen organisational knowledge and capability in relation to Technical Specifications for Interoperability (TSI) certification and the accreditation process for acting as a Notified Body (NoBo). The customer is involved in high-speed rail systems and required a structured understanding of authorisation processes applicable to rolling stock and infrastructure projects.

Increasing regulatory complexity and evolving European authorisation requirements made it necessary to build internal competence in certification workflows, roles, and responsibilities. The objective of the project was to establish a clear, practical and reliable framework for understanding, structuring, and managing TSI-related authorisation activities across different project types.

PROSE delivered interactive, on-site training workshops tailored to the customer’s specific role and regulatory context. Our approach combined structured theoretical input with practical examples drawn from real TSI certification and authorisation projects across the European railway sector.

Key elements of the TSI framework, the NNTRs, the CSM Regulation, the role of a Notified Body (NoBo), a Designated Body (DeBo), an Independent Assessment Body (AsBo), and typical certification and authorisation processes were explained step by step and discussed in detail with the participants. Throughout the workshops, PROSE addressed customer-specific questions and scenarios, ensuring direct applicability to ongoing and future activities.

Customer benefit

Through its collaboration with PROSE, the client gained a clear, structured and practical understanding of the certification and approval processes in accordance with the TSI, NNTR and other safety regulations. The training strengthened internal competence and confidence in dealing with regulatory requirements and interactions with external stakeholders.

PROSE’s independent position and broad industry experience ensured an objective and practice-oriented perspective, grounded in real-world railway projects. This enabled the customer to build sustainable internal know-how, reduce dependency on external clarification, and establish a solid foundation for future certification and accreditation activities.

Digital rail lubrication system visual with train, data analytics and route-based monitoring in a depot environment.

Research creates value when it works in daily operation

Our research showed what intelligent, data-based rail head lubrication can achieve and how this understanding has developed systemically.

The next step is crucial: transferring the research results into a real operational project. A concrete example of this is the implementation at BERNMOBIL, in collaboration with Substring as technology partner.

Based on the findings from the research, a system was implemented that:

  • Records the lubrication requirements on the vehicle side
  • Continuously evaluates noise and operating data
  • Triggers lubrication proactively and route-specifically

What is different from before is that lubrication is now demand-driven, data-based and comprehensive across the entire fleet. The principles developed in the research project were specifically refined for operational use with a focus on robustness, scalability and integration into existing processes.

The result is a practical solution that reduces noise and minimises wear while taking operational and environmental requirements into account.

Further insights into the project can be found here: https://prose.one/noise-and-wear-reduction-for-trams-with-ai-based-rail-head-lubrication/

Conference setting with audience and speaker, overlaid with AI, train and engineering system icons representing intelligent rail optimisation.

Intelligent systems in rail transport must be considered as part of the overall system

Data-based rail head lubrication can significantly influence noise, wear and resource use. However, operators increasingly see that such solutions must be considered in the wider context of traction, braking and daily operation.

That is why we are placing the topic in a broader technical context:

On 23 April 2026 in Vienna, Dr Felix Saur, our expert in wheel-rail systems, will give a presentation at the 23rd Oberbremsrätekonferenz and the 21st International Central European Conference, an event organised by Knorr-Bremse GmbH Austria, on Intelligent traction optimisation of rail vehicles.

The conference offers another important platform for exchange between operations, technology and research, especially where friction, traction, braking and vehicle dynamics come together.

Reach out to Dr Felix Saur or Josef  Kometer to meet up. We look forward to dialogue and discussion with the expert community.

Further information on the event can be found here: https://www.oberbremsraetekonferenz.eu/cms/

Hyperloop capsule vehicles in tube infrastructure, illustrating maglev transport concept and advanced bogie design development.

HyperTransfer: Assessment of conceptual bogie design

Customer: HYPERLOOP Transportation Technologies Inc., USA

Project tasks

  • Review and assessment of existing conceptual bogie and chassis designs
  • Technical clarification with the customer and co-development partners
  • Development of a multibody simulation (MBS) model of the HyperTransfer vehicle
  • Representation of magnetic levitation forces using simplified spring models
  • Modelling all relevant kinematic degrees of freedom
  • Integration of mechanical backup suspension systems (wheels and/or skids) to analyse limit cases and residual clearances

Our approach

The project supported the early development and feasibility assessment of a magnetic levitation vehicle within the HyperTransfer concept developed by HYPERLOOP Transportation Technologies. The vehicle represents a new class of guided transport systems, combining railway vehicle engineering principles and magnetic levitation (maglev) technology.

In an initial step, the customer required an independent assessment of a conceptual bogie and chassis design to support ongoing feasibility studies and early design decisions. This required engineering expertise with proven experience in rolling stock design as well as magnetic levitation systems.

In subsequent development phases, the feasibility assessment of the HyperTransfer vehicle required a detailed multibody simulation (MBS) model. The model enabled dynamic simulations, derivation ofload assumptions, and kinematic analyses, providing a technical basis to support further design and validation activities.

PROSE applied a structured two-step engineering approach tailored to the early development phase of the HyperTransfer vehicle.

In the first step, we reviewed the existing design documentation, formulated targeted technical questions, and performed an independent assessment of the conceptual bogie and chassis design. This work was carried out in close collaboration with the HYPERLOOPTT design team and its co-development partners through technical meetings and focused design reviews.

In the second step, PROSE developed a multibody simulation (MBS) model representing the HyperTransfer vehicle. The model includes the capsule, the secondary suspension between capsule and chassis, and the load-carrying chassis components up to the primary suspension interface to the levitation magnets.

PROSE’s combination of railway vehicle engineering expertise and specific know-how in magnetic levitation systems differentiated our approach and ensured a technically robust and application-oriented solution.

Customer benefit

By working with PROSE, the customer received independent and experienced engineering support during a critical early development phase of the HyperTransfer concept. PROSE’s in-depth expertise in chassis and railway vehicle design, combined with practical experience in magnetic levitation systems provided valuable technical assurance.

The structured assessment and simulation-based approach enabled the customer to make informed design decisions identify technical constraints at an early stage, and reduce development risks.

PROSE’s ability to bridge conventional railway engineering and advanced maglev concepts enabled the customer in progressing efficiently from concept evaluation towards detailed development, with a clear and technically robust basis for further design activities.

 

TILO FLIRT train of SBB in Switzerland during service life extension project, modern electric multiple unit on track.

Vehicle life extension TILO FLIRT

Customer: SBB, Switzerland

Project tasks

  • Overall project management of the TILO FLIRT service life extension
  • Project reporting to the steering committee
  • Project planning and realisation of the detailed concept phase
  • Funding application ARPV
  • Project planning and implementation of the realisation phase
  • Leading the SBB project team

Our approach

Swiss Federal Railways (SBB) operates 54 Flirt trains with TILO. These trains were purchased in five phases between 2007 and 2020 and were designed for a service life of 25 years. In order to be able to replace all TILO Flirt trains simultaneously as part of a new procurement project, SBB plans to extend the service life of the two oldest sub-fleets to 32 years.

PROSE is responsible for the overall management of the project to extend the service life of the TILO train fleet. Over 2 ½ years, we led a dedicated project team within SBB, ensuring seamless collaboration between customer requirements, technology, development, production, quality, and supply chain management.

A key milestone was the detailed concept phase, where PROSE’s structured approach ensured that requirements management, technical concept development, and prototype conversion were all completed on time and within budget. Our expertise in certification played a crucial role in securing the necessary licences for both Switzerland and Italy, a fundamental step in keeping the project on track.
PROSE also spearheaded the successful funding application (ARPV) to the responsible cantons and the Federal Office of Transport (FOT), securing approval to finance the conversion of the entire fleet of 30 trains.

During the production phase, we worked closely with the SBB production plant to ensure a smooth transition to series conversion. With production successfully underway, PROSE carefully handed over the project to SBB, ensuring continued progress and a reliable future for the TILO fleet.

Customer benefit

With PROSE as a partner, the customer benefits from comprehensive expertise in the areas of project management, stakeholder management, project planning, change management and cost control. An entrepreneurial approach, sound technical knowledge, but also knowledge of SBB processes and organisation are essential for successful project implementation.

Beyond technical know-how, our understanding of SBB’s processes and organisation was a key factor in keeping the project on track. By working with PROSE, the customer was able to bridge resource gaps, tap into our extensive railway industry network, and benefit from independent, expert advice that led to a successful project outcome.

 

    

Two trains in Dresden and Vienna with AI icons illustrating intelligent rail head lubrication, acoustic monitoring and data-driven rail optimisation.

From Dresden to Vienna: one shared challenge

Over the past two weeks, PROSE brought intelligent rail head lubrication into two key industry forums in Dresden and Vienna. We used these events to test ideas, challenge assumptions and engage with the people who deal with these challenges every day.

In Dresden, at the 21st International Railway Vehicle Conference, the focus was on intelligent rail head conditioning for trams. The combination of measurement technology, AI-supported data analysis and practical operational results sparked strong interest and many follow-up questions, both technical and operational.

In Vienna, at the 30th meeting of the Sound and Vibration Working Group (Rail Transport), the discussion shifted towards vehicle-based acoustic monitoring. The topic of acoustic data collection as the basis for tailored rail head conditioning and monitoring of rolling stock and infrastructure led to in-depth exchanges.

What stood out across both events:

There is a growing awareness that noise, wear and resource use cannot be optimised in isolation. For operators, maintainers and engineers, the key question is becoming:
How do we turn data into reliable, scalable decisions in daily operation?

These conversations build directly on the insights from our intelligent rail head lubrication research project and help translate them into practical, scalable solutions.

AI-based tram rail lubrication system showing data acquisition from acoustics and GPS, fleet swarm intelligence, and predictive lubrication decisions.

Noise and wear reduction for trams with AI-based rail head lubrication

Customer: BERNMOBIL, Switzerland

Project tasks

  • Project management
  • Concept development
  • System integration
  • Data analysis

Our approach

The operation of a railway vehicle causes noise and wear on wheels and rails. These issues can be reduced by lubricating the wheel-rail contact point. However, excessive lubrication can pose a safety problem, as it reduces traction forces and increases braking distance, potentially causing ecological pollution.

Together with our partners, we have developed a system as part of a research project supported by the Federal Office of Transport (FOT) that makes it possible to condition the rail head as needed. Sensors installed on the vehicle measure status parameters and feed them to an AI installed on the vehicle. The machine learning model analyses the data, determines the need for conditioning and synchronises this with other vehicles operating on the rail network. Based on this information, each vehicle decides for itself at which point in the rail network conditioning must be initiated by the on-board lubrication system.

Customer benefit

In addition to fully automatic lubrication, the customer has access to comprehensive noise monitoring, which allows sources of noise to be localised at an early stage if they have not already been completely eliminated by the system. Since relevant influencing variables are known through the machine learning model, most noise sources can already be detected predictively and avoided altogether.

Communication between the vehicles creates a form of fleet-wide intelligence, enabling complete coverage of the fleet and the entire route network without having to equip each individual vehicle with expensive measurement technology. Thanks to the measuring system installed, other conditions can be monitored in addition to noise, such as ride comfort, wear between wheel and rail, and the infrastructure.

The customer benefits from our deep understanding of wheel–rail interaction and tram system behaviour, as well as our hands-on technical engagement throughout development.

 

   

Intelligent rail head conditioning workflow showing research, validation, publication and implementation for data-driven lubrication in urban rail systems.

Turning research into publication

Our research project on intelligent rail head lubrication has shown what is technically possible when lubrication is controlled on the basis of real operational data.

Now the topic has entered the professional debate.

In the issue of ZEVrail, a detailed technical article has been published. The article presents the joint project carried out by BERNMOBIL, Substring and PROSE, funded by the Swiss Federal Office of Transport (BAV), and describes:

  • The concept of demand-driven rail head lubrication
  • Acoustic monitoring across 15 tram vehicles
  • AI-based evaluation of audio, meta and weather data
  • Predictive triggering of lubrication based on noise mapping
  • The transition from static lubrication to data-driven system control

What began as a research question “How to reduce curve squeal and wear with minimal use of lubrication agents?”  has evolved into a validated, scalable system approach.

The publication shows that intelligent rail head lubrication is becoming part of the technical conversation about sustainable urban rail operations.

Read the article here (only in German): https://www.zevrail.de/artikel/die-intelligente-schienenkopfkonditionierung

 

Illustration of a connected train with C-DAS and ATO trackside platform showing automated train operation, data connectivity and driver advisory system.

Co-leading the Driver Advisory System and trackside platform for Automated Train Operation

Customer: Rhätische Bahn AG, Switzerland

Project tasks

  • Project management
  • Requirements capture
  • Conceptdevelopment
  • Bogie andcarbody development
  • System integration

Our approach

Rhätische Bahn AG (RhB) plans to introduce a smart cruise control (SCC) function on its latest generation of multiple units as part of their automation strategy. The SCC function specifies an optimised speed and controls acceleration and braking between two station stops. In accordance with SN EN 62267, the SCC function is classified as Grade of Automation 1 (GoA1), as speed monitoring under the operating regulations (FDV) continues to be carried out by the locomotive crew.

A trackside platform (xx-TS) is planned for the SCC function. This trackside platform provides the necessary route and timetable data. It is based on existing specifications such as Automated Train Operation over European Train Control System (ATO over ETCS) in accordance with the Technical Specification for Interoperability relating to Control-Command and Signalling Subsystems (TSI CCS) and Connected Driver Advisory System (C-DAS). After registering with the train number, the train receives journey and segment profiles in accordance with SUBSET-126/SFERA. Transmission takes place via a mobile communications interface.

With the introduction of a Traffic Management System (TMS), a networked driver assistance system (C-DAS) will also be implemented, which displays energy-efficient and conflict-free driving recommendations based on optimised production specifications from the TMS.

PROSE was involved in the railway automation programme as co-project manager. We implemented a four-stage approach within the ATO-TS/C-DAS project:

  1. Existing requirements and specifications for the operational target vision were recorded and compared with the status quo of the ATO, TMS and C-DAS systems.
  2. Once the target vision and target architecture had been defined, a structured market evaluation was carried out and interviews were conducted with various system providers.
  3. Based on the market evaluation, a two-stage assessment of the solution options was carried out and proposals for the procurement strategy were developed.
  4. Further steps were implemented for the ATO-TS and C-DAS subsystems, including the execution of an RFI and in-depth analyses with selected providers.

Customer benefit

Thanks to our previous involvement in the railway automation programme and our combined operational and technical expertise, we were able to structure and advance the project with clear direction and efficiency.

Based on our market knowledge and cross-project experience, we were able to develop solution scenarios tailored to RhB’s operating environment. We moderated structured discussions with internal experts and programme participants, creating transparent decision-making and a solid foundation for the next implementation phase.

PROSE provided independent technical assessment, clear methodology and procurement support, laying the foundation for a clearly defined architecture and reduced implementation risk.

 

  

 

Illustration of a tpf train between Planchy depot and Bulle station showing automated shunting operations and digital signalling.

Conducting a feasibility study for fully automated shunting operations

Customer: tpf SA, Switzerland

Project tasks

  • Project management
  • Operational target
  • Technical feasibility assessment
  • Analysis of operational processes
  • Cost-benefit analysis

Our approach

The metre-gauge rolling stock used by the transport publics fribourgeois (tpf) operating on the Palézieux – Bulle – Montbovon line is maintained at the Planchy depot in the industrial zone of Bulle. The distance between Bulle station and the depot is around one kilometre. In current operations, staff must walk between the station and depot to perform shunting movements, which limits operational efficiency.

As part of recent service expansion , the infrastructure around Bulle has been modernised to current technical standards. In parallel with the planned modernisation of the Planchy maintenance facility, tpf investigated whether fully automated shunting operations using Automatic Train Operation Grade of Automation 4 (ATO GoA4) could be implemented with the existing vehicle fleet within the Planchy – Bulle area. The study assessed technical feasibility, operational implications, and the economic viability of introducing automated shunting.

PROSE supported tpf SA throughout the entire feasibility study in a structured, multi-stage process involving operational, technical, and management stakeholders. We first analysed the current operational processes, infrastructure, and regulatory conditions. Based on this, we jointly developed a target operating concept for automated shunting.

To evaluate possible implementation strategies, PROSE performed a risk analysis and developed several technically consistent solution variants using a morphological analysis method. These options were then compared through a transparent cost-benefit assessment, enabling a structured evaluation of technical feasibility and operational impact.

Customer benefit

tpf SA received a clear and independent decision basis for the further development of the Planchy maintenance site.

Thanks to the efficient approach, initial results were quickly developed in collaboration with tpf experts and presented to management. Technical feasibility, operational implications and economic effects were presented in a comprehensible and transparent manner.

With our expertise in railway operations and ATO realistic implementation scenarios were developed and efficiently aligned with internal stakeholders. PROSE also supported tpf in initial discussions with potential system suppliers, strengthening tpf’s technical and strategic position.

 

  

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