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.
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.
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
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.
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.
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.
