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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.

 

    

Vande Bharat train at platform – sleeping car unit representing bogie design validation project in India.

Design validation of bogies for Vande Bharat sleeping cars

Customer: Ramkrishna Forgings Limited, India

Project tasks

  • Bogie design validation
  • Creation of 3D models for all bogie types
  • FEA of the bogie frame types and high-loaded components
  • Preparation of bogie frame fatigue test specification
  • Welding inspection onsite
  • Update of existing drawings to improve manufacturing quality

Our approach

PROSE was commissioned by RAMKRISHNA FORGINGS LIMITED (RKFL) to perform independent design validation of the bogie assemblies for the new sleeping car coaches of the Vande Bharat train. The work focused on verifying the structural and functional compliance of the existing passenger car bogie for the sleeping car configuration. We performed Finite Element Analysis (FEA) and assessed conformity with relevant railway standards, providing the technical justification required to support the design modifications and approval for operation.

PROSE provided RAMKRISHNA FORGINGS LIMITED (RKFL) with independent technical validation of the bogie design for the sleeping car configuration of the Vande Bharat train. Drawing on our expertise in structural, safety and system analysis, and our deep understanding of international railway standards, we ensured a reliable and efficient assessment of the existing design

Customer benefit

As an independent engineering partner, PROSE supported RKFL from analysis through testing and documentation, helping to secure the operational readiness and approval of the new sleeping cars for service on the Indian rail network. Furthermore, RKFL receives manufacturing documents tailored to RKFL’s production capabilities.

 

    

Open door of a C20 metro driver cab in Sweden, illustrating onboard modifications and the need for verified electrical documentation.

Documenting a reconstructed electrical design for a metro driver cab air conditioning system

Customer: MTR Tech AB, Sweden

Project tasks

  • Collection of as-built electrical information from customer
  • Technical review and consolidation of handwritten updates
  • Reconstruction of electrical schematics
  • Verification of correctness and consistency
  • Formal release of approved drawings

Our approach

The project addressed the absence of controlled and verified electrical documentation following the installation of a new air-conditioning unit in the driver cab of a C20 metro vehicle operating in Sweden. The modification had been implemented by the customer, with electrical schematics updated manually, resulting in missing traceability, inconsistent information, and non-compliance with railway documentation standards. The objective was to reconstruct the as-built installation, verify the electrical design, and formally document and release correct, complete and compliant electrical drawings.

PROSE collected and reviewed all available technical input from the customer, including as-built installation details and handwritten updates to existing schematics. Based on this information, we analysed, consolidated, and reconstructed the electrical design and documented it into formal electrical schematics in accordance with applicable railway documentation standards. The resulting drawings were verified and issued under PROSE authorship, in close coordination with the customer’s engineers, ensuring accuracy, traceability, and controlled release. PROSE’s independence and deep understanding of railway electrical systems enabled efficient reconstruction even with incomplete and informal source material.

Customer benefit

By selecting PROSE, the customer obtained verified and formally released electrical documentation that accurately reflects the as-built installation. This restored full traceability, ensured compliance with railway documentation standards, and created a reliable basis for safe operation, maintenance, and future modifications. PROSE’s independent engineering approach and experience in reconstructing and validating modified or legacy designs reduced project risk and relieved pressure on the customer’s internal engineering resources.

 

   

Assembly of a red funicular carriage with new air suspension chassis during the modernisation of an alpine funicular railway, accompanied by PROSE.

Chassis development funicular railway

Customer: Steurer Seilbahnen AG, Switzerland

Project tasks

  • Project management
  • Weight management
  • Feasibility study
  • Concept development
  • Verification concept and load assumptions
  • Strength calculation
  • Manufacturing support

Our approach

As part of the modernisation of the funicular railway from Unterwasser to Iltios in the Toggenburg region, Steurer Seilbahnen AG selected PROSE as its partner for the development of a custom running gear with air suspension – specially designed for funicular railway applications.

Steurer Seilbahnen AG has designed an innovative concept for a funicular railway chassis with air suspension and one-sided longitudinal force transmission. Building on this foundation, PROSE worked with Steurer to develop detailed requirements specification and carried out a concept validation. The constructive realisation was carried out at Steurer with technical support and coordination from PROSE. Our team handled the full structural design and strength verification, including equalisation safety. We also defined the measuring point plan for the test runs and delivered a comprehensive comparison report to support strength validation. To ensure an optimal solution, close cooperation between all parties involved was key during the iterations between design and strength.

Customer benefit

The combination of Steurer’s and PROSE’s expertise in funicular railways and air suspension resulted in a constructive and efficient co-operation that always kept an eye on all aspects, right through to verification. PROSE’s flexibility and proactive project management – together with Steurer’s practical insight – enabled design optimisations to be seamlessly integrated during procurement and manufacturing. This close cooperation ensured a technically sound, thoroughly verified solution tailored to the specific needs of funicular railways.

 

        

Bogie development for a shunting locomotive

Customer: SCHÖMA Lokomotiven GmbH, Germany

Project tasks

  • Project management
  • Concept development
  • System analysis, System specification, System integration, system design
  • Construction of 3D model of bogie
  • Strength calculation according to EN 13749
  • Proof of driving safety and derailment safety according to EN 14363
  • Bolt calculation in accordance with VDI 2230
  • Design Reviews with peers

Technical data

  • Track gauge: 1435 mm
  • Speed: 80 km/h
  • Minimum track curve radius: 90 m
  • Distance between bogie pivots: 5.8 m
  • Centre distance: 2 m
  • Frame length: 11.8 m
  • Vehicle mass: 60 t
  • Bogie mass less than: 8.8 t
  • Mass of the car body (m1) approx.: 40.4 – 43.4 tons
  • Maximum vehicle mass: 61 t
  • Minimum vehicle mass: 58 t
  • Maximum wheelset load: 15.25 t

Our approach

The project is part of a shunting locomotive platform programme in which SCHÖMA supplied a shunting locomotive to Alstom for a transport authority in Manila, Philippines. The vehicle is a four-axle, diesel-hydraulically driven shunting locomotive for standard gauge with a total vehicle mass of 60 tonnes. PROSE was commissioned to carry out the complete mechanical development of the bogie.

The scope included the design and engineering of the bogie frame, wheelsets, axle boxes, and the integration of all relevant systems and components. A key technical focus was the limited available installation space and, the safe transmission of longitudinal traction and braking forces from the bogie to the carbody, without significantly altering wheelset loads. The project therefore required a robust, space-efficient, and safety-compliant bogie design suitable for effective production and reliable operation.

At PROSE, rail vehicle development follows the V-model in accordance with EN 50126. For this project, the bogie development was focused on the concept design and final design phases, ensuring an efficient and targeted engineering process. Throughout the development, PROSE placed particular emphasis on a production-oriented design approach, using cost-effective and manufacturing-friendly welded structures wherever possible.

In parallel, the design was optimised regarding both production and life-cycle costs, while consistently meeting safety and performance requirements. Compliance with all relevant safety-related EN standards was embedded in the design process. PROSE’s extensive experience in bogie engineering and our deep understanding of standards and manufacturing constraints enabled a balanced and efficient development approach tailored to the customer’s needs.

Customer benefit

Thanks to the timely and successful completion of the project, the customer received rapid and reliable engineering support within a short timeframe. By selecting PROSE, the customer benefited from in-depth expertise in bogie development, significantly reducing internal effort and development time. PROSE delivered a complete, production-ready bogie design, including a full 3D model, proof of strength, track guidance analysis, and detailed component specifications to support procurement.

All relevant systems, including primary and secondary suspension dampers, gearbox, brake system, and longitudinal and transverse stops, were successfully integrated. The critical challenge of transmitting longitudinal forces without increasing wheelset loads was solved through a cranked pull/push rod with a deep linkage connected to a balancer, resulting in low pitching moments and stable wheelset behaviour. Although no specific standards were required by the end customer, PROSE provided comprehensive and standard-compliant proofs of strength and derailment safety, demonstrating conformity with relevant standards such as EN 13749:2024, EN 13979, DVS 1612 and EN 14363:2016.

 

 

Blue and white Västtrafik tram on route 3 to Kålltorp travelling through a historic city street in Gothenburg, Sweden.

Reverse engineering of new gears and housing for trams

Customer: Västtrafik AB, Sweden

Project tasks

  • Measuring of the gearbox housing
  • 3D modelling and technical drawings
  • Material definition
  • Definition of applicable standards
  • Risk assessment
  • Criteria for quality control

Our approach

PROSE applied a hybrid reverse-engineering method that combined mobile 3D scanning, mesh processing, and feature-based CAD modelling to reconstruct the gear housing. In parallel, we coordinated with the third-party supplier Zoerkler to perform precision gear measurement, material analysis, and hardness verification.
All interfaces, tolerances, and functional surfaces were systematically cross-checked against the physical components and validated through a structured CSM-RA risk assessment.
Based on these inputs, PROSE established updated 3D/2D documentation and a technical specification defining material, heat treatment, tolerances and surface-finish requirements in accordance with railway safety and documentation standards.

Customer benefit

The long-term availability of spare parts is ensured through updated and complete technical documentation that enables reliable future manufacturing of spare parts. This significantly reduces the risk of obsolescence for the parts involved.
Thanks to PROSE’s hybrid reverse-engineering approach, combining mobile 3D scanning, mesh processing, and feature-based Computer-Aided Design (CAD) modelling, the technical documentation was delivered in a time-efficient manner. At the same time, we ensured an uncompromised level of safety and quality compared with the current gearbox parts.
Throughout the project, PROSE maintained continuous dialogue with all involved actors to achieve solutions that meet the customer’s needs, supported by our independent position and broad engineering expertise.

 

Railway axle handling equipment with a workshop fixture and CAD model of the axle lift and support console

Design and delivery of an axle lift and support console

Customer: Göteborgs Spårvägar, Sweden

Project tasks

  • Requirement capture
  • Engineering design
  • Manufacturing and logistics
  • Delivery within time, budget and quality
  • Training
  • Verification

Our approach

Our engineering team worked closely with the customer to define the functional and safety requirements for the axle lift and support console. Based on these inputs, we created the original design delivered three years ago, providing a stable and safe solution for axle handling.  For the repeat order, we coordinated the detailed design updates and worked with one of our trusted manufacturing partners to produce the second unit. This follow-up delivery allowed us to refine the proven concept with targeted improvements informed by the customer’s operational experience.

Throughout the project, we ensured clear communication, organised the necessary verification steps, and provided training to support safe and consistent use in the workshop.

Customer benefit

​The customer receives a fixture that supports safer and more controlled axle handling in the workshop. The design reduces the risk of axle movement and helps protect personnel and equipment during maintenance activities.
By working with PROSE, the customer benefits from a partner capable of managing the full chain from requirement capture to design, manufacturing coordination, verification, and training. Our independent engineering approach and familiarity with workshop processes ensure that the delivered solution is practical, reliable, and straightforward to integrate.
The decision to procure a second unit confirms that the original solution met the customer’s expectations and that the updated version continues to support their operational needs.

 

 

Mounted bogie swivel arm assembly with rollers and fastened components during workshop installation.

Training for the assembly of bogie components

Customer: Alstom Schweiz AG, Switzerland

Project tasks

  • Training
  • Technical documentation
  • Organisation of the training

Our approach

PROSE supplied Alstom Switzerland with the swivel arm units for the GoldenPass Express bogie and created the assembly and maintenance instructions. Now, both Alstom and the end customer sought PROSE’s expertise to provide comprehensive training in assembly and testing.

PROSE carried out a multiple-day training course at the customer’s site, using the existing installation, maintenance, and work instructions as a foundation. The participating personnel were instructed step by step on how to perform the tasks independently. Our training covered the entire process, from preparation to mechanical, pneumatic and electrical assembly, as well as component testing and the creation of test protocols.

Customer benefit

As PROSE had already been responsible for and accompanied the assembly of the entire series, the customer was able to benefit from our extensive expertise and take over the assembly activities independently within a very short time.

 

Blue and red trains at a snowy outdoor station platform at night, illustrating rail coupler upgrade and electrical interface integration for snowblower wagon type B257

Coupler upgrade and electrical interface integration

Customer: MTR Tech AB, Sweden

Project tasks

  • Requirements capture and definition of electrical interface
  • Design review
  • Update of technical documentation
  • Verification of electrical connections and signal integrity
  • Official drawing release and configuration control
  • Coordination with MTR during implementation and validation

Our approach

PROSE contributed to the design definition of the new electrical interface and collaborated closely with MTR engineers during system implementation of the upgraded coupling system be-tween the Snowblower Wagon Type B257 and the C20 train.
While MTR carried out on-site installation and testing, we re-viewed, clarified, and consolidated the draft electrical updates and ensured that all connections and signal interfaces complied with safety and operational requirements.
The verified and approved information was issued as official electrical drawings, released under PROSE authorship and re-viewed by MTR engineers.
This cooperative approach ensured full traceability, correctness, and compliance with railway documentation standards.

Customer benefit

​The customer gained a reliable and standardised coupling solution that reduced manual work in demanding winter conditions. The upgraded interface improved operational efficiency by ensuring full mechanical and electrical com-patibility between the snowblower wagon and the C20 fleet. Independent engineering review by PROSE ensured high quality and compliant documentation, providing confi-dence in the safety and integrity of the system. The result is a future-ready solution that supports safe, efficient, and well-documented winter operations.

 

 

Investigation on European EMU brake systems

Customer: leading international brake equipment manufacturer

Project tasks

  • Project management
  • Requirements capture
  • Concept development
  • System integration

Our approach

The project aimed to assist a leading international brake equipment manufacturer in navigating the complex landscape of European brake system regulations, generic design principles, and requirements for brake certification. The primary challenge was to provide the manufacturer with a consistent and clear understanding of these regulations to facilitate the development and certification of their brake systems for the European market. This support was crucial for ensuring compliance with stringent European safety standards and improving the manufacturer’s competitive edge in the international market.

Based on publicly available information and own experiences, PROSE provided a comprehensive investigation report with following main chapters:

  • European and American design philosophy and safety principles for emergency braking in EMU
  • Brake performance of current EMU train designs in Europe
  • Redundancy on emergency braking command and functions
  • Emergency Braking according EN 16185-1 and EN 15734-1
  • Brake system requirements for EMUs according to European TSI regulations
  • Brake system control signal according to EN 15611:2020

Customer benefit

As a result of this project, PROSE’s customer obtained an in-depth and detailed understanding of the general requirements and best practices associated with European EMU brake design. This comprehensive insight enabled the manufacturer to align their products with European standards, thereby enhancing their ability to meet certification requirements. Additionally, the detailed investigation report served as a valuable reference for the customer’s engineering and design teams, facilitating informed decision-making and innovation in brake system design. Overall, the project significantly boosted the customer’s capability to produce compliant, reliable, and competitive brake systems for the European rail market.

 

      

Design and authorisation strategy for a rail-bound maintenance machine

Customer: SCHÖMA, Germany

Project tasks

  • Vehicle authorisation strategy
  • Design assurance (Systems Engineering)
  • Concept development
  • Technical evaluation of offers and technical coordination with suppliers
  • Project management

Our approach

SCHÖMA plans to develop a proven, powered, three-part rail-bound maintenance machine with cab, loading platform and crane called HERO. SCHÖMA needs support in developing the authorisation strategy to fulfil the EN 14033 standards and in defining the design process including verification and validation.

PROSE developed the decision-making basis for the authorisation process enabling a defined combination of the three vehicles of the working machine to be approved and the verifications and evidence according to EN 14033 to be provided. PROSE also supported SCHÖMA in the budget planning phase of the development of the HERO work machine in the evaluation of supplier offers for systems and components such as the power train, braking system, power generation, train protection (ETCS) and heating, ventilation and air conditioning (HVAC). In addition, PROSE defined the design phases and the design assurance process according to the systems engineering methodology to ensure a defined and structured design process.

Customer benefit

PROSE has structured and optimised SCHÖMA’s development process by systematically applying the system engineering methodology. This approach has not only minimised development risks associated with costs and timelines but has crucially enhanced the predictability and likelihood of obtaining the necessary authorisation.

 

          

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