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Author: Livia In-Albon

Centralising the ICN tilting train maintenance – Variant study for maintenance work in a short shop

Customer: SBB Passenger Traffic, Switzerland

Project tasks

  • Project management
  • Variant assessment
  • Operating and production concept
  • Compilation of profitability calculation

Our Approach

Together with various SBB organisations and several specialist planners (L2A Architekten AG, Technisches Büro K.N.O.L.L. GmbH, Wiederkehr und Villiger AG and Fahrgrund AG), 12 variants were developed in the greater Biel area and evaluated operationally, technically, and economically. Planning documents, a cost estimate, a possible schedule, and the corresponding application documentation for the decision-making process within SBB were prepared for the best variant. In addition, a recommendation was made for further procedures, including the risk assessment for the subsequent phases.

Customer benefit

With the wealth of experience of the people involved, the possibilities at the Biel site could be quickly and efficiently identified and evaluated. The option of additional roof work was subsequently integrated due to the consideration of the entire production concept.

 

Strength analysis (FEA simulation)

Customer: various customers

Project tasks

Development of verification concepts and load assumptions as well as performance of calculations and simulations for:

  • Car bodies according to e.g. EN 12663
  • Bogies and wheelsets according to e.g. EN 13749, EN 13261
  • Streetcars and metros according to VDV 152
  • Attachment parts according to EN 61373
  • General load assumptions from calculations, measurements and simulations for e.g. special vehicles

Static, fatigue and time strength assessment:

  • Base material and weld seams according to FKM Guideline
  • Fatigue of steel according to Eurocode 3 DIN EN 1993-1-9 and BS 7608
  • Weld seam evaluation according to DVS 1612 / DVS 1608 and IIW recommendation
  • Screw connection according to DIN 25202:1-6, VDI 2230 and Eurocode 3 DIN EN 1993-1-8
  • Cylindrical helical spring according to EN 13906

Further analyses:

  • Nonlinear and crash analyses
  • Heat transfer analyses
  • Topological optimizations
  • Eigenvalue analyses
  • Stability analyses
  • Damage analyses and repair solutions

Our Approach

Depending on the customer’s specifications, PROSE carries out strength analyses in parallel with the design in its own development team or works directly with the customer’s team. PROSE covers the entire range of the analysis from the development of the load assumptions to the modelling to the efficient execution of the calculations and simulations as well as the evaluation of the results. Based on the strength analyses, PROSE can prepare test specifications for structural tests, accompany tests and, if required, validate the strength model with the evaluation. PROSE engineers have interdisciplinary know-how also in non-railway specific problems. Furthermore, PROSE also takes over the coaching of simulation processes and supports as a neutral consultant.

Customer benefit

Through the early use of strength analyses in the design process, weak points are identified and eliminated at an early stage, costly test series are avoided and the quality of the product is decisively improved. In addition to a qualified calculation, PROSE attaches great importance to the interpretation and presentation of the results required for the customer, including explanations and, if necessary, documentation relevant for approval. Due to its great flexibility, PROSE can respond to customer requests at very short notice

        

Evaluation of offers for new KVG tram vehicles

Customer: Kasseler Verkehrs-Gesellschaft, Germany

Project tasks

  • Answering bidders’ technical questions
  • Support during the presentation of the workshop infrastructure to the bidders
  • Development of criteria for the evaluation-relevant requirements
  • Evaluation of the indicative offers regarding the fulfilment of the technical specifications
  • Preparing, assisting, and recording negotiations
  • Evaluation of binding offers regarding the fulfilment of the technical specification

Our Approach

PROSE assists the Kasseler Verkehrs-Gesellschaft (KVG) with technical expertise from the time of publication of the tender until the award of the contract. KVG was supported particularly in the priority areas of:

  • Answering bidders’ questions
  • Bid evaluation and
  • Support during bidder discussions

Based on the technical specifications, which were developed with the support of PROSE, the bidders’ questions were answered. PROSE established a small agile team for the bid evaluation, which started the intensive and systematic evaluation after receipt of the bids. The team was engaged in the same composition for the indicative as well as for the binding offers. In addition to adhering to the demanding schedule, this required close coordination with the KVG project team. At a joint workshop on-site in Kassel, the bidder discussions were prepared, and criteria for the evaluation-relevant requirements were developed.

Customer benefit

The customer can benefit from broad and independent expert support by PROSE:

  • Reduced binding of own resources for the development of the requirement specification.
  • Supplementing own technical knowledge with external knowledge for the general vehicle concept and the associated subsystems and components
  • Drawing on experience from PROSE’s broad pool of experts
  • Fast, structured and always comprehensible processing of the evaluation of almost 2000 requirements and 200 offer documents
  • Support in the preparation of the award decision

   

Door opener project in ATO and DTO

We are shaping tomorrow’s mobility by being a mobility service provider. In our project “Feasibility study on driverless train operation (DTO)” we had the opportunity to show and observe the market within driverless operation / ATO.

The project was a cornerstone in bringing our capabilities in rolling stock operation together, both on technical as well as on operational aspects. The customer, BLT Transport AG, in Switzerland received a well-founded result based on a diversified analysis. During the realisation of the project, BLT already received an overview of the current state of the art of autonomous transport systems and of present projects. In the end PROSE developed a coordinated proposal for a step by step introduction of autonomous operation, as well as further steps required for implementation, which were coordinated with the Federal Office of Transport (FOT).

Interested in shaping tomorrows mobility together? Let us know how we can support in your projects: https://prose.one/contact/

 

Auditing vehicle maintenance

Customer: Appenzeller Bahnen, Switzerland

Project tasks

  • Organisation
  • Workshop inspection
  • Consolidation
  • Report

Our Approach

PROSE implemented the maintenance audit in four sections: The content and objective of the first part was the deductive immersion in the maintenance organisation, starting from the strategy, the annual report on the structural and process organisation, the basic compatibility assessment of functional process organisations and the cooperation and division of labour between the different workshops. In the second part of this audit, two workshops were visited and their work was evaluated with regard to the knowledge gained in the first part and any gaps and/or suggestions for improvement were collected. Finally, the collected impressions were summarised and reflected upon and located with the client. The final report documented the result of the external view and provided information on the development status of vehicle maintenance.

Customer benefit

During the four abovementioned inspections, the Appenzeller Bahnen and their maintenance team received valuable feedback on their processes, on the organisation of procedures and processes, as well as on the status of their documentation. A number of suggestions for improvement were gratefully received and implemented as soon as possible.

 

ATO GoA2 over ETCS and national Class B Systems Requirements Capture and Approval Risks Analysis

Customer: Nederlandse Spoorwegen, Netherlands

Project tasks

  • Vehicle Authorisation Management and Strategy
  • Operational concepts
  • Automatic Train Operation (ATO)
  • Requirements Analysis
  • Roll out Concept

Our Approach

PROSE analysed possible risks in the homologation and deployment of ATO GoA2 over ATB via STM-Module and analysed the requirements for ATO out of the TSI CCS and TSI OPE. Through analysing project risks concerning existing standards, approval processes and the target architecture, PROSE provided an in-depth analysis proposing a vehicle authorisation approach that covers the overall system level and the changes to the technical and operational subsystems. Besides an approval concept, PROSE provided a roll-out approach for ATO that mitigates safety risks related to Human-Machine-Interface.

Customer benefit

NS benefits from PROSE’s in-depth analysis and concept as an independent second opinion and the adaptation of experiences gained in other ATO projects. Due to the extensive overall system knowledge, PROSE was able to consider all relevant subsystems of railway operation and technology and deliver an NS-aligned approach.

Approval support snow blower zb

Customer: ZAUGG AG Eggiwil, Switzerland

Project tasks

  • Proof of derailment, restriction and strength
  • Expert reports on fire protection, derailment and restriction

Our Approach

The AB-EBV requires a proof of compliance with the reference line. For this proof, PROSE has prepared a restriction calculation according to EN 15273-2:2013 as well as an independent expert report. The front and side windows are glued to the cabin of the snow blower. ZAUGG is not certified according to DIN 6701, but will have the bonding work carried out by an external company. PROSE has been commissioned to provide proof of strength for the two A1 bondings. In addition, the AB-EBV requires an expert report on the fire protection concept, which has been prepared by PROSE experts. PROSE has also provided the proof of derailment safety according to the BAV guideline “Nachweis sicheres Fahrverhalten Meterspur-, Spezialspur- und Zahnradbahnen”, as well as an independent expert report.

Customer benefit

PROSE’s expertise in the topics of verification as well as its comprehensive knowledge made it possible to use independent experts for the preparation of the expert report. For this reason, time was saved and ZAUGG was able to submit the required documents to the BAV on time.

Fire protection monitoring technology IC 2000

Customer: SBB, Switzerland

Project tasks

  • Risk analysis for fire protection of the technical components
  • Conceptual design of fire protection monitoring
  • Integration concepts for the different vehicles
  • Electrical integration
  • Complete installation and maintenance documentation
  • Verification documents for approval

Our Approach

Beforehand, PROSE had already developed an initial concept for the cable routing and carried out a risk analysis of the affected components. Together with the component supplier, PROSE then developed a detailed concept for the mechanical integration of the LHD cable and the other components required for monitoring in the vehicles. After the conversion of the first prototypes, the complete documentation as well as the proofs for the approval were prepared by PROSE.

Customer benefit

In particular, the customer was able to benefit from the comprehensive know-how of PROSE’s experts, who were able to comprehensively narrow down the complex topic of fire protection monitoring and its integration based on their knowledge of the vehicles. Due to the intensive support of the workshop, questions could be clarified immediately and thus the target dates could be optimally met.

Development Connection Magnetic Rail Brake Locomotive Gmf 4/4

Customer: Rhätische Bahn, Switzerland

Project tasks

  • Geometric investigations
  • Risk analysis with expert opinion
  • Rough and detailed concept
  • Clearance verification (gauging)
  • Strength verification
  • Approval support

Our Approach

In the first phase, PROSE, as the developer of the motor bogie, was commissioned by the RhB with a geometric investigation, which showed that the possibility of slippage of the MTR in unfavourable situations could not be excluded. In a second phase, PROSE prepared an expert opinion describing under which conditions (operational, system characteristics, etc.) safe operation with the four service traction units Gmf 4/4 can be guaranteed until the completion of the conversion. This statement is intended as a basis for an RhB-internal risk assessment. In the last phase, PROSE developed a rough and detailed concept with gauging (clearance) and strength verification for a cross connection of the MTR arranged on both sides of the engine bogie of the locomotive Gmf 4/4. In addition, PROSE supported the customer in preparing the documents relevant for approval according to the regulation RTE 49100.

Customer benefit

Due to the detailed system knowledge of the bogie and the contribution of expertise in connection with the safety-relevant operation, the customer was able to remedy the malfunction with the most efficient measures possible. PROSE’s competence in vehicle authorisation also helped the client to submit the required documents to the Federal Office of Transport FOT in due time.

Leadership Coaching and Strategy Consulting Digital Interlocking

Customer: SBB Infrastructure, Switzerland

Project tasks

  • Leadership Coaching
  • Strategy Consulting
  • Stakeholder Management

Our Approach

PROSE is carrying out the leadership coaching and strategy consulting for the SBB project manager “EESA 3.1 – Industrialised Rollout”. The leadership coaching was conducted between the poles of the rollout implementation, defined in the directional decision, and the call for tenders, which had to be prepared concurrently. On the one hand, the time constraints associated with the implementation were addressed, which led to good progress in the conceptual and content-related work. On the other hand, the strategy consultation dealt with prioritising the tender contents, whereby the implementation of innovations and the inclusion of essential rollout requirements were subordinated to securing the contract.

Customer benefit

In addition to more minor and continuous further developments of concepts, significant successes were also achieved in some areas. From a project management perspective, the following topics deserve special attention:

  • Publication of EULYNX Baseline 4.1 with the necessary adaptations for Switzerland.
  • Concluded procurement of a proof-of-concept platform for the Object Controller to demonstrate software separation, security features and a reference implementation of the Rail Safe Transport Application (RaST).
  • Results of the first iteration in the study, “Expandability using the example of the Dagmersellen – Emmenbrücke line”, showing a cost-saving potential between 50% and 75%.
  • Make-or-buy workshop with infrastructure management

Finite element analysis and strength verification for folding seats in the AS coach

Customer: FAINSA, Spain

Project tasks

  • Strength calculation of the folding seats
  • Proposals for optimisation and recalculation of the design
  • Final verification calculation with final report

Our Approach

In order to be able to implement the project, CAD 3D models of three seat types were provided by the customer. The models were read into the FEA software by PROSE and analysed. Based on the results and in close cooperation with the customer, various optimisations of the designs were made. These optimisations were recalculated and, if necessary, further improved in the construction. After the optimised designs met the requirements of UIC566, a final report could be prepared with the proof of strength requested by SBB. This report was required as an initial type test document and also served the end customer as a verification document for the seats in order to obtain approval for the passenger coaches.

Customer benefit

Our engineering services provide the customer with optimised seat designs whose strength can be verified. The knowledge of the approval processes and the end customer-specific requirements enable PROSE to create “approval-proof” documents that can be accepted by the end customer. Our knowledge of local conditions and experience as an internationally active company enables us to build a technical and formal bridge between the seat supplier and the end customer.

Brake and thermal calculation locomotive Aaem841

Customer: Müller Technologie AG, Switzerland

Project tasks

  • Define and obtain input data
  • Brake calculation in TrainBrac
  • Thermal calculation in ANSYS
  • Specification and selection matrix for brake blocks

Our Approach

PROSE defines and procures the input data based on the relevant standards, which are required for the approval of the vehicle. Subsequently, the calculations were carried out and optimized so that the defined requirements were met. For this purpose, a brake calculation in TrainBrac was created in close coordination with the customer, as well as a thermal brake calculation in ANSYS, in order to prove the performance of the brake.  PROSE also contacted various brake block suppliers for possible linings on the basis of the specifications and calculation results and prepared a selection and decision matrix for Müller Technologie AG, including recommendations for the selection of a suitable lining.

Customer benefit

Thanks to PROSE’s expertise in this field, the customer receives documents to prove the performance of the modernised brake, which comply with the relevant standards and can thus be submitted 1:1 to the assessor/expert to achieve approval. Furthermore, the specification and pre-evaluation of the brake blocks material with decision support enables an efficient enquiry of possible suppliers.

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