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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 approval strategy for a rail-bound maintenance machine

Customer: SCHÖMA, Germany

Project tasks

  • Vehicle authoirsation 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 approval 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 necessary approvals from authorities.

 

          

Vehicle Authorisation

Customer: various customers

Project tasks

  • Carrying out requirements capture and preparing the safety evaluation, including risk analysis
  • Preparation and management of evidence documents
  • Cooperation and coordination of NoBo, DeBo and AsBo
  • Support in preparing several declarations and dealing with online registers like ERATV or ERADIS
  • Management of the change notification to the ERA or national safety authorities like EBA for changes not requiring an authorisation
  • Management of authorisation applications via One Stop Shop to the ERA for changes requiring authorisation
  • Coordination with the ERA and national safety authority

Our Approach

Vehicle operators or leasing companies make changes to their vehicles for very different reasons, e.g. for obsolescence reasons or to offer passengers a better service by customising the interior and adding features such as sockets or WLAN. In addition to providing engineering services, PROSE supports such projects by taking over the entire approval management process, including communication with all the bodies and authorities involved.

The authorisation process ensures safe rail transport and the best possible interoperability throughout the EU. However, implementing changes to rolling stock presents a significant challenge to operators, keepers, and owners.

At PROSE, we recognise that each railway vehicle is unique. Our team of experts develops vehicle authorisation strategies that address the specific challenges of our customer’s products and needs. From Requirements Capture to One Stop Shop, our experts have the knowledge to guide you through the process. Whether you only need assistance with a single task or are looking for a complete solution, we can provide solutions to meet your particular requirements.

Customer benefit

Modernisations and retrofits guarantee enhanced reliability and superior passenger comfort and open up new applications by integrating new systems. Whilst operators and workshops can focus on their primary tasks, PROSE can handle all the “paperwork” from the engineering and the preparation of evidence documents to the assessment and authorisation phases with bodies and authorities involved. Due to our comprehensive service portfolio, we help reduce interfaces and effort because all services are coordinated and come from a single source.

PROSE ensures that our customers’ railway vehicles comply with the latest standards and regulations. From document preparation to submission, we make sure that vehicle approval hurdles don’t derail your success.

 

      

Expert report for approval of new trams in Dortmund

Customer: HeiterBlick GmbH, Germany

Project tasks

  • ​Assessment of running dynamics

Our Approach

For the approval of the new trams of the operator DSW21 in Dortmund, the manufacturer HeiterBlick GmbH in Leipzig commissioned the EBA-approved expert Stefan Bühler to assess the running dynamic behaviour according to the regulations for trams in Germany, BOStrab.

The new vehicles have been authorised and in operation since April 2024. Modernised vehicles will be assessed in a further phase.

​PROSE agreed on the scope of verification with the technical supervisory authority of North Rhine-Westphalia (TAB NRW) and the manufacturer HeiterBlick GmbH. Dr Johannes Keudel, a specialist in running dynamics simulations, supported Stefan Bühler in the assessment of the provided evidence. Finally, the expert report was drawn up.

Customer benefit

It is essential for the customer that the authorities accept the assessors. Thanks to the appraisal team’s high level of expertise, the customer HeiterBlick GmbH knew precisely what evidence he had to provide and in what form. For this reason and thanks to the high level of customer orientation of the PROSE team, the expert report could be prepared quickly and in good quality. Although the input on this specialist area was only available very late, this hardly caused any delay to the authorization of the trams.

 

Expert report on metre-gauge flat wagons with cogwheel brake

Customer: PVF Trade, s.r.o., Czech Republic

Project tasks

  • Project management
  • Definition and procurement of input data
  • Review and appraisal of all input documents
  • Preparation of expert report

Our Approach

PROSE was commissioned by the company PVF Trade, s.r.o., to prepare an expert test report (SV report) on the test report of suspension tests of the vehicle “four-axle service – flat wagon 1000mm track with cogwheel brake”.

The report is intended to provide information on the compliance of the brake tests according to the test report “Flat wagon with toothed wheel brake suspension tests” with the provisions of the AB-EBV and their fulfilment.

All documents submitted were checked for completeness and plausibility. The check was carried out against all relevant requirements from the FOT guidelines AB-EBV.

In the event of inconsistencies and/or missing information, these were requested from the client or other project partners. On this basis, a final expert report was prepared and submitted to the client.

Customer benefit

​PROSE’s prompt preparation of the expert report guarantees a smooth and rapid handling of the authorisation procedure. The intensive review of the documents provided ensures that the report meets the highest quality standards and that the vehicle is guaranteed to operate safely. The intensive project supervision by the PROSE expert regarding adjustments and requirements for the documentation with all project partners relieves the customer of this organisational work and ensures rapid and high-quality processing.

 

 

Expert opinion on carbody structures

Project tasks

Verification of

  • Design Concept and Philosophy
  • Carbody calculation specification
  • Carbody crash specification
  • Validation plan
  • Finite element descriptive document
  • Calculation results
  • Weldings

Our Approach

PROSE supported the established European rail vehicle manufacturer with reviews to ensure that the development of its carbody structures complies with all requirements (safety, durability, strength/rigidity) specified in the standards and is supplemented by customer requirements.

Two essential characteristics of carbody structure are crashworthiness and fatigue strength. To check these properties, design principles and calculation methods must be evaluated.

The evaluation focused on the customer’s stress report, which PROSE carefully checked. In addition to evidence of carbody straining by standardised loads, evidence of results from load scenarios in the end customer’s country is required. Such load scenarios are not directly defined in a standard but must be analysed. As this task is more complex, PROSE scrutinised this part of the report with particular attention.

Customer benefit

PROSE helped ensure the development of a cutting-edge aluminium carbody structure. The customer and the end customer highly valued its independent expert opinion as quality assurance.

With PROSE as an independent assessor, the customers had a further means of reducing design risks by using the expertise of PROSE’s seasoned engineers.

 

  

Requirements for battery vehicles

Customer: SBB AG, Switzerland

Project tasks

  • Review of the standard requirements catalogue
  • Classification of the requirements
  • Categorisation and adaptation of requirements
  • Integration of the requirements into the requirements management system
  • Evaluation of the offers
  • Conversion and import of the requirements specification

Our Approach

Swiss Federal Railways SBB is preparing for the tender to procure new vehicles that replace the Tm 234 fleets of the first, second, and third series. These new vehicles must fulfil the operational requirements of both existing fleets and be climate-neutral. As the Federal Office of Transport (FOT) has yet to approve finalised regulations for battery-powered vehicles, SBB is facing challenges regarding the approval of battery operation. Therefore, SBB needs support for the battery subsystem to correctly integrate the specific requirements for the battery system into the specifications.

PROSE supported SBB in reviewing the content of the standard requirements catalogue for the battery subsystem (SAK – System Batterie). The task included not only suggesting content adjustments and additions but also classifying the requirements into functional and non-functional categories. In addition, PROSE categorised and adapted the requirements according to the “MUST” and “SHOULD” criteria and submitted proposals for weighting these criteria for the evaluation matrix.

Based on this preliminary work, the specified requirements were integrated into the requirements management system Re-qSuite®. There, the requirements were evaluated individually, and a corresponding binding force was given to evaluate the bids received in the upcoming tender. The specifications were then converted into a format that SBB could import into its requirements management system, Polari-on®.

Customer benefit

SBB received a clear catalogue of questions and an annotated requirement specification, which made the requirements more precise and easier to understand. Checking, evaluating, and identifying requirements that require a risk assessment contribute to quality assurance and minimise potential risks in the project. The risk assessment and the binding nature of the requirements enable better preparation for the tender, which improves the quality of the bids received. Converting the specifications into a compatible format for SBB’s requirements management system ensures smooth integration and utilisation of the requirements by the customer.

 

Welding drawings and calculations for repairing Magnetic Brakes

Project tasks

  • Scanning of specific parts
  • Drafting welding drawings
  • Performing design calculations
  • Clarifying questions about the deformed magnetic brake
  • Project management

Our Approach

PROSE used precise scans of the magnetic rail brakes to create customised welding drawings and detailed documentation for their repair. This work included the development of technical drawings and calculation documents tailored to the specific requirements of the brakes. Our approach ensured that the repairs met the highest safety standards and could be carried out efficiently. By providing comprehensive guidance for the welding work, we ensured our customer could perform the necessary repairs accurately. Our commitment to quality and technical excellence enabled a sustainable solution to restore the functionality and safety of the magnetic rail brakes.

Customer benefit

With the welding drawings supplied by PROSE, the customer is now able to repair deformations on magnetic rail brakes accurately and efficiently. These customised drawings enable the customer’s team to carry out accurate repairs that restore the brakes’ performance and safety. The direct benefits to the customer include significantly reduced downtime, cost savings through in-house repair capability, and extending the life of critical brake system components. These customised solutions ensure that the magnetic brakes maintain their essential function in the safety and efficiency of rail transport.

 

Fire Safety Assessment and Consulting

Project tasks

  • Consultancy
  • Development and creation of fire protection concepts
  • Development and creation of evacuation concepts
  • Analyses of fire protection requirements
  • Compilation of required fire protection test reports
  • Communication with authorities, manufacturers and testing laboratories
  • Integration of fire safety systems
  • Preparation of approval documents relevant to fire protection

Our Approach

PROSE analyses the given situation and develops solutions that meet the applicable fire protection requirements. To this end, PROSE advises the customer and identifies various solutions in order to find an efficient way of achieving the required fire protection for railway vehicles in accordance with EN 45545. Our experts calculate the thermal load of the vehicle during the design and propose measures for its reduction.

Customer benefit

The customer benefits from our many years of experience in the field of fire protection for all types of rail vehicles in accordance with EN 45545, including not only advice but also the creation of concepts, the preparation of the necessary fire protection certificates, contact with manufacturers of fire protection-compliant components and communication with approval authorities. The aim is to place fire protection suitable vehicles into service.

PROSE Documentation services – Technical documentation

Project tasks

  • Technical writing
  • Information analysis
  • Document management
  • Review process work
  • Coordination of projects
  • Administration and management
  • Translation: Terminology management (English, German, Swedish)
  • Document management system PRO(doc)

Our Approach

PROSE assists in the creation and translation of new technical documentation, as well as revising and updating existing documents. Our technical writers help you create technical documents such as technical descriptions, maintenance manuals and spare parts lists. We review, both on the supplier and customer side, the language, structure, and contents of the technical documents, and perform quality control in line with established documentation requirements.

The technical writers produce technical documentation, working both in office and together with technicians and system engineers on site, to understand complex functioning of products and systems, thus creating clear documentation. The quality is assured through detailed checklists, verification on site and validation with the customer.

PROSE’s technical translators work with the support of professional translation software. The creation of custom dictionaries allows us to help you manage your company-specific terminology. At PROSE, we offer translation to, and from, Swedish, English and German.

We also offer our own document management system, PRO(doc). PRO(doc) is a customised online documentation management system. Developed by PROSE, it enables you to easily manage your documentation, such as technical drawings, maintenance instructions, trouble-shooting remedial actions, spare parts information and so on.

Customer benefit

PROSE has contributed to many projects by creating new technical documents, as well as by translation, review and coordination. The documents are written for train drivers, maintenance staff and training instructors, are verified on site and validated with the customer.

PROSE works both on the supplier side and on the customer side, contributing to a large amount of important documentation. Work in the depot environment ensures that complex functions are understood, to create clear documentation. This helps operators to understand the updated products and systems, ensures correct use of the products and enables and guarantees safety in maintenance work.

Vehicle procurement – Manufacturing Supervision, Quality Control and Factory Tests

Customer: various customer

Project tasks

  • Acceptance of the welded car bodies / bogie frames
  • Paint inspection and acceptance
  • Intermediate acceptance of main electrical components
  • Intermediate acceptance of interior fittings
  • Factory acceptance/customer acceptance

Our Approach

By regular participation in the vehicle acceptance tests and constant coordination with the team of the vehicle manufacturer, PROSE checks the quality of the production. The customer is permanently kept up to date by the acceptance team regarding the progress of the production as well as possible complications or deadline postponements. He immediately receives the results of the production controls and acceptances and can follow up changes, modifications etc.

The dates for the acceptance of components, intermediate assembly stands and vehicles ready for delivery follow the production plan but are also handled operationally and flexibly in order to be able to react to specific occasions. In this way, control of the construction process is always ensured and there is the possibility of intervention in the event of difficulties such as quality slumps, scheduling, supply, or capacity problems.

Customer benefit

With manufacturing supervision, the manufacturer’s quality assurance process is checked and monitored in addition to the product quality, because every vehicle has gone through this process before it is presented for factory acceptance. Continuous construction supervision ensures consistent quality at a high level.

      

Managing system and electrical engineering for a tramway

Project tasks

  • Project management
  • System engineering
  • Electrical engineering

Our Approach

Managing the systems engineering of tramways demands a methodological and detail-oriented approach. Bearing the technical responsibility for systems and electrical engineering in the new rail vehicles, our approach is characterised by precision, innovation, and meticulous attention to every intricate detail. We ensure that every aspect aligns with the highest industry standards.

Customer benefit

Our commitment to overseeing tramway systems engineering delivers tangible benefits to our customers. By assuming comprehensive technical responsibility for the systems and electrical engineering of the new rail vehicles, along with substantial involvement in their development, we guarantee a product of unmatched quality. For the vehicles, this translates into enhanced reliability, operational efficiency, and cutting-edge innovation, where our customers are granted risk mitigation, shorter time to market and overall satisfaction at every turn.

     

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