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Author: Livia In-Albon

Technician using augmented reality interface for digital train inspection and maintenance in a railway workshop

Implementing Digital Maintenance with Augmented Reality

Project tasks

  • Defining a relevant digital maintenance use case
  • Parametrising the AR-based inspection system
  • Localising software and adapting interfaces
  • Setting up and supporting an on-site pilot project
  • Training personnel and supporting prototype testing
  • Evaluating results and delivering an application report

Our approach

PROSE implemented an AR-supported prototype for a railway sector customer as part of a pilot project to digitalise maintenance processes for bogies. The objective was to replace paper-based inspection workflows and improve data quality and traceability.

The selected use case covered dimensional inspection under defined load conditions with structured checkpoints and tolerances. PROSE digitalised existing inspection processes and transformed them into guided digital workflows for mobile devices and AR headsets. Nominal values and wear limits were integrated to ensure systematic inspections and direct recording of deviations. The application enables hands-free operation as well as structured real-time data capture and further processing.

The pilot project included configuration of the application, execution under real workshop conditions, and evaluation with regard to usability, data quality, and operational limits.

PROSE combined railway engineering expertise with digital technology know-how and worked with a specialised AR partner.

We defined a suitable use case together with the customer and implemented it directly on-site as part of the pilot project. We configured and validated the application iteratively based on real maintenance processes.

Our approach included close collaboration with customer personnel, rapid adaptation of digital workflows, and targeted training of users.

Customer benefit

The customer received a validated prototype demonstrating how digital and AR-supported maintenance can improve efficiency and quality. Paper-based processes are reduced, training time is shortened, and inspections become more consistent and guided.

Hands-free operation and real-time documentation improve usability and data quality in workshop environments. At the same time, digital records enhance traceability and support integration into existing maintenance systems.

Through PROSE’s independent expertise and cross-industry insights, the customer gained a solid basis for further development and implementation of digital maintenance solutions.

 

Fault tree diagram showing hazard decomposition into SIL 4–1 functions with logic gates and events for railway safety analysis.

Designing a safety strategy for embedded onboard systems in railway applications

Project tasks

  • Defining Safety Integrity Level (SIL) classification methods across international regulatory frameworks (CSM DT, CENELEC, RSSB, ANSF, ANSI, GOST, SIRF, IEC 61508 risk graph)
  • Describing and applying the interaction between Failure Modes and Effects Analysis (FMEA) and Fault Tree Analysis (FTA)
  • Developing a structured safety strategy (e.g. top-down and function-oriented approaches) for embedded onboard systems
  • Establishing a safety case concept based on safety-critical and safety-related functions, including visualisation (e.g. Goal Structuring Notation (GSN))
  • Specifying safety evidence documentation, including content, key messages, and effort estimation for Independent Safety Assessor (ISA) approval

Our approach

The project covered the development of a generic application for embedded onboard systems (hardware and software) on rolling stock, intended for use across multiple regions, including the European Union, the United Kingdom, and international markets.

Furthermore, the project included the definition of a safety process and strategy for systems up to Safety Integrity Level 2 (SIL 2), with consideration for scalability to higher integrity levels. The interaction between Failure Modes and Effects Analysis (FMEA) and Fault Tree Analysis (FTA) was described and demonstrated through application examples.

The project also included the determination of suitable SIL classification methods based on applicable regulatory frameworks such as CSM DT, RSSB, ANSF, ANSI, GOST, SIRF, and CENELEC. In addition, the alignment of qualitative and quantitative safety metrics across these standards was also considered.

Relevant directives ((EU) 402/2013, (EU) 2015/1136) and standards (e.g. EN 50129, EN 50716, IEC 61508) defined the regulatory and methodological framework for the safety process and documentation.

PROSE created a comprehensive safety plan covering system, hardware, software, and communication aspects of a generic onboard application. Our approach combined regulatory analysis with practical safety engineering methods, ensuring alignment between international standards and project-specific requirements.

We defined a structured safety demonstration concept, forming the basis for all safety activities and evidence generation. By aligning methodologies such as Failure Modes and Effects Analysis (FMEA) and Fault Tree Analysis (FTA), we ensured a consistent safety process.

Customer benefit

The safety plan provides a structured foundation for all safety activities throughout the project lifecycle, covering system, hardware, and software levels. It forms a key part of the documentation submitted to the Independent Safety Assessor (ISA), supporting the development and evaluation of the final safety case.

By establishing a harmonised and reusable safety process, the customer can efficiently apply the strategy to future generic applications while ensuring compliance with CENELEC and International Electrotechnical Commission (IEC) standards.

The defined safety strategy enables scalability from Basic Integrity up to SIL 4 and supports the development of robust safety cases based on clearly structured safety functions. PROSE’s independent and methodical approach ensures transparency, regulatory compliance, and long-term usability across international markets.

 

      

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

 

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