Failure mode effects and criticality analysis (FMECA)
Our Approach
PROSE has created the fire protection analysis and the corresponding fire protection material list for VOGT. Furthermore, input data were collected for LCC and FMECA analyses. These data were inserted in the project-specific templates. As a result, documents were created according to the specifications of the end customer.
Customer benefit
PROSE has taken responsibility for VOGT to provide the correct input data for Fire Protection, LCC, and FMEC analyses and to create the documents by the end-customer accepted quality. This relieved VOGT of tasks that are outside their core business.
Compilation and preparation of parameters for modelling and simulation
Determination of the braking scenario to be considered
Creation of a multi-body simulation model (MBS model) of the rack railway container wagon to be investigated, as well as of the coupled train configuration
Execution and evaluation of the simulation
Documentation in an evidence report
Our Approach
At first, PROSE compiled all parameters required for modelling and simulation based on the customer’s data. Subsequently, the braking scenario relevant to the approval was determined and agreed upon with the customer. PROSE created the rack railway container wagon’s multi-body simulation model (MBS model) in the required modelling depth. The overall model of the train included a simplified MBS model of a flat wagon and the already at PROSE existing model of an HGe 4/4 II locomotive. PROSE simulated the most critical operational cases and documented the results and assessment of the simulations in an evidence report for the approval authority.
Customer benefit
The customer received an evidence report for the approval documentation, which clearly and comprehensibly documents the computational proof of the safety against the derailment of the rack railway container wagon. Based on the evidence, the customer received the approval for the wagon.
New vehicle developments:
Feasibility studies, risk analysis (failure conditions) and support of concept studies based on computer simulations
Vehicle approval:
Simulations for the assessment of running characteristics, model validation, simulations for the extension of approvals, simulations related to track access charges
Investigation of operational issues:
Clarification of causes for derailments, assessment of the effects of changes, analysis of unexpected wear, wheel-rail interface studies
Special operational conditions:
Pushing/pulling of inoperable multiple units, propelling tests
Wheel set torsional vibrations
Special applications such as gauge changing bogies, maglev or (suspended) monorails
Our Approach
PROSE has many years of experience in the dynamic simulation of rail vehicles, acquired through the running dynamic analyses for various own bogie developments and many calculations for manufacturers and operators. PROSE has also supported various innovative developments and research projects. Due to this expertise, PROSE is the suitable partner for the investigation of challenging questions in the field of rail vehicle dynamics. Through analyses and simulations, PROSE helps customers to identify weak points at an early stage, to avoid costly test series and to decisively improve the quality of the products.
PROSE covers the entire range of simulation steps, from the definition of the simulation task, the system boundary conditions and the compilation of the required model parameters to efficient model building, execution of the simulations and evaluation of the results. Based on many years of experience, PROSE is able to reliably estimate parameters which are difficult to determine and to select the appropriate modelling depth for the respective problem. The commercial simulation software system SIMPACK as well as special applications developed in-house are available for the calculations. Depending on customer requirements, PROSE carries out analyses in parallel to the design process in the own development team or as part of the customer’s team. PROSE also contributes with interdisciplinary know-how to non-railway-specific solutions.
Customer benefit
Qualified simulations reduce the development risk or help to solve problems that have occurred. In addition to a qualified calculation, PROSE attaches great importance to the interpretation and presentation of the results to the customer, including in-depth explanations and the necessary formal documentation relevant to homologation if requested. PROSE can also provide coaching support for simulation processes and act as a neutral consultant. Due to a flexible organisation, PROSE can respond to customer requests at very short notice.
MBS-calculations to evaluate safety against derailment in track twists based on the EN14363:2019
Investigation with cranes in transfer mode and in two different working positions
Determining of existing reserves of the lifting load
Presentation of the results regarding the EN14033-2:2017 appendix H to the technical supervisory authority (TAB)
Our Approach
PROSE created an MBS model of the track vehicle and simulated runs through critical curves with superelevation and maximum track twist considering the specifications from the EN14363 for the vehicle in transfer mode and in two different working positions with corresponding crane position and lifting load.
Customer benefit
With the MBS-simulations PROSE was able to prove the safety against derailment of the track vehicle in twisting sections of track by calculations and to determine the existing reserves of the lifting load in the two working positions. Furthermore, the results are used in the approval process as a presentation for the technical supervisory authority (TAB).
Structural strength analysis of RGM 2-24 grinding vehicle car body main structure
Creation of mid-surface Finite Element Model (FEM)
Definition of load case and boundaries conditions
Interpretation of simulation result according to EN12663-2010
Creation of structural strength report
Comparison of result according to additional norms (VDV-Schrift 152 10/2016 BoStrab & BS 7608:2014)
Our Approach
L&S contracted PROSE to demonstrate the strength of the RGM-2-24 main car body structure as per EN 12663-1 by means of a finite element analysis (FEA). We did create a 3D model for calculation, define the loads cases together with L&S, perform the simulation, assess the results with final presentation in a report. We also did support with design adaptation where required to reach EN 12663 fulfilment.
Customer benefit
By contracting PROSE, L&S did benefit from our wide experience in structural strength analysis. This led to faster and efficient design integrity calculation and adaptation of design when required to ensure structural integrity of the rail grinding vehicle car body main structure.
Checking and compilation of the modeling parameters
Checking the implementation of the boundary conditions in the simulation environment
Evaluation of the results
Expert support and access to leading industry knowledge
Key supporter of technology development
Our Approach
Traila requested the support of PROSE to validate their simulation concepts and testing scenarios using the industry standard SIMPACK. In addition, PROSE was requested to validate the derailment safety analysis needed to successfully operate a test tram on the VBZ network. Traila developed a Matlab-based simulation model using Simscape MBD for system integration analysis purposes, as standard and detailed wheel-rail contact models for their application were not available at the time. Traila continues to invest in their simulation capabilities, to support the extensive development of the Traila technology.
Customer benefit
“Due to the extensive experience of the experts at PROSE with MBD modeling of rail vehicles, Traila was able to perform the derailment safety verification quickly, efficiently and successfully,” according to Dr. Tom Morris CEO of Traila. “Additionally, PROSE was quick to react and provide support when we needed it.”
For the following connections, bonding proofs were developed on the basis of FEM calculations:
Car body structure – front cabin
Front cabin – front window
Front cabin – side window
Front cabin – rear view mirror
Front cabin – headlights
Front cabin – handle
PROSE prepared the strength verifications and adhesive drawings of the A1 bonding’s according to DIN 6701. In advance, the loads were determined according to EN 14067-5 and the load cases were defined according to EN 12663. Afterwards, the relevant load cases were evaluated and documented in the report.
Customer benefit
PROSE’s experience and certification in accordance with “DIN 6701, bonding of rail vehicles”, helps the customer to able to complete the verification dossier and thus obtain flawless re-registration of the vehicle.
Structural strength analysis of SAMMS-t710 freight vehicle.
Creation of mid-surface Finite Element Model (FEM)
Definition of load case and boundaries conditions
Interpretation of simulation result according to EN12663-2010
Creation of structural strength report
Our Approach
L&S contracted PROSE to demonstrate the strength of the SAMMS-t710 modification they designed as per EN 12663-1 by means of a finite element analysis (FEA). PROSE did assess the design modification in light of EN 15085-3:2010, then create a 3D model for calculation, define the loads cases together with L&S, perform the simulation, assess the results with presentation in a report. We also did support with design adaptation where required to reach EN 12663 fulfilment.
Customer benefit
By contracting PROSE, L&S did benefit from our wide experience in structural strength analysis. This led to faster and efficient design integrity calculation and adaptation of design when required to ensure structural integrity of the rail grinding vehicle car body main structure.
Procuring rail vehicles has never been as complex as it is today, especially for small and medium-sized operators. Global market consolidation, shrinking supplier pools and increasing technical requirements are pushing many to their limits.
Our latest PROSE white paper shows how you can minimise risks when procuring small fleets through:
Targeted support from experts
Life cycle-oriented procurement planning
Long-term harmonised strategies for rail vehicles
With concrete case studies such as the VDV tram-train tender and the collaboration with MGB, RhB and zb
Clarification of the intended track layout, speed restrictions and wheel/rail profile conditions
Setup of appropriate multi body system (MBS) models of the tracks including the cross-sections of the switch blades as well as three types of existing tram vehicles
Conduction of a variation of MBS simulation runs and extraction of loads acting on track components like e.g. rails, switch tongues; setup of related load assumptions
Setup of a finite element model (FEM) e.g. of the switch tongues and the surrounding structure
Fatigue strength assessment of the track component while applying the loads as gained from the MBS simulations
Proposals of design improvements regarding the strength
Meter gauge tram application
Tracks including deep grooved switches
Our Approach
Running dynamics simulations have been performed to determine the wheel/rail loads, which are acting on the related track components. The specific conditions of WSB have been considered while conducting multi body system (MBS) simulations for all three types of vehicles in all relevant directions of travel through the triangular joint “Sanderring” as well as the tracks in front of the central railway station. As a result, load assumptions for the track components under assessment (e.g. switch tongues) have been extracted from the MBS simulations. A finite element model (FEM) of the component and the surrounding structure was set up. The wheel/rail load assumptions as derived from the MBS simulations have been applied to the FEM model. A fatigue assessment was conducted while analyzing the strength amplitude as deriving from the maximum strength. Based on the FEM results, specific design adjustments have been recommended to improve the strength.
Customer benefit
One major benefit is the minimization of the risk e.g. of occurrence of cracks. This is especially important, as new tram vehicles by tendency come along with higher axle loads and are thus more demanding regarding the strength of track components. Another benefit is the reusability of the load assumptions as well as the strength analysis for future tenders of similar track layouts under comparable conditions. Two of the three MBS vehicle models have already been setup in a former project for WSB. Thus, the benefit of reusability without initial modelling efforts was already used in this project.
