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Aerodynamics simulation (CFD)

Customer: Various customers

Project tasks

​During the development process or during modernisation, aerodynamic influences such as crosswind or vehicle air conditioning of a vehicle must be assessed. Often the final verification requires investigations in a wind tunnel or climatic wind tunnel. However, CFD (Computational fluid dynamics) simulations are ideal for an initial assessment and optimization, as they generally provide reliable results at significantly lower cost.

Analyses:

  • Crosswind stability (aero-dynamic coefficients and wind characteristics curves) according to EN 14067-6
  • Climatic studies and thermal comfort

Our Approach

Crosswind assessment according to EN 14067-6

The EN 14067-6 provides for the evaluation of crosswind with aerodynamic coefficients, which can be obtained either by wind tunnel tests or by CFD simulations. PROSE can determine these coefficients by CFD simulations and derive characteristic wind curves. The influence of the vehicle design on the crosswind stability can be considered in the design phase. In the case of changes to the vehicle exterior shape during conversions, the influence can be assessed and in the case of minor changes, proof of crosswind stability can also be provided.

Investigation of vehicle air conditioning

CFD simulations allow first estimations for climatic-technical investigations according to European standards, which are based on tests in the climatic wind tunnel. An optimization with CFD simulations within the scope of the design of the air conditioning system generates additional safety and can avoid costly adjustments and repetitions of measurements in the climatic wind tunnel.

Customer benefit

PROSE can support you during the development process or during a modernization with CFD simulations to reduce costs and risks of wind tunnel and climatic wind tunnel tests.

 

 

Mechanical design and system integration

Customer: Various customers

Project tasks

  • Development projects:
    • Complete bogie design according to EN 15085
    • Complete car body design according to EN 15085
    • Interior and layout design
    • System integration (e.g. doors, brake system, HVAC, coupler etc.)
  • Vehicle modernisation projects:
    • Interior design
    • Layout concepts
    • System integration (e.g. ATC, infotainment system, magnetic rail brake, air conditioning system etc.)
  • Niche development projects (e.g. gauge changing and rack railway bogie, people mover or magnetic levitation systems etc.)
  • Structural bonding & welding competences:
    • Bonding according to DIN 6701-3 (A1) / EN 17460
    • Welding according to EN 15085-2 (CL 1)

Our Approach

Our focus is on the manufacturability and maintainability of a vehicle. We offer thought-through solutions in all our de-signs. We remain in direct exchange with our customer to ensure that the design process can be finished in a short time.

Customer benefit

With 3D model views we give visual answers to your ideas or thoughts. We have an agile way of working and can ensure that your feedback is shaping the visual idea and helping to complete it. Already in an early stage of the design process, the PROSE designer team ensures that the concept design is feasible. Our flexibility makes us respond to your requests at very short notice. We offer the complete batch of documentation for procurement and manufacturing.

 

Wheelset torsional vibration

Customer: Various customers

Project tasks

  • Basic assessment of the vehicle’s wheelset torsional dynamics
  • Analytical estimation for dimensioning the wheelset shaft and, if necessary, other components
  • Multibody simulations for a more detailed analysis for optimization
  • Consulting and support for homologation measurements and support for documentation for homologation.

Our Approach

PROSE accompanies the entire, or single sections of the process chain, from the pre-design of the wheelset shaft over the optimization of the mechanical components up to the execution
of the homologation measurements for the determination of the maximum, dynamic torsional moment. By means of analytical and conceptual investigations, a fundamental assessment of the wheelset torsional dynamics of the vehicle is already carried out in advance, taking into account the dimensioning of the wheelset, the powertrain configuration and drive systems. Based on the preliminary investigations, in-depth analyses are carried out in consultation with the customer using multibody simulation models. On the one hand, these investigations limit
the maximum dynamic torsional moment to be expected, indicate the component loads to be expected and, at the same time, describe other dynamic properties of the driveline. Considering the existing driveline configuration, its design properties are optimized in such a way that the mechanical damping of the first torsional eigenmode of the wheelset is increased, thereby reducing the maximum dynamic torsional moment. The results of the analyses provide relevant information for the system analysis required for certification, which describes the wheelset torsional dynamics of the vehicle. In addition, the analyses are used to determine the vehicle configurations critical for planning and performing the homologation measurements. Finally, the maximum dynamic torsional moment is determined with metrological tests on the vehicle.

Customer benefit

The analyses carried out help the customer to minimize risks in the approval of the wheelsets. The preliminary investigations enable realistic time and cost planning up to the approval of
the wheelsets. The in-depth analyses and component optimizations reduce the stresses caused by torsional vibrations and prevent damage to safety-relevant components during operation. Finally, the identification of critical operating conditions significantly reduces and secures the scope of the homologation measurement.

 

Fire protection, LCC and FMECA for water cannons

Customer: Vogt AG, Switzerland

Project tasks

  • Acquisition of input data
  • Fire protection analysis
  • LCC analysis
  • 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.

Requirements elicitation and preparation of test concept for perception system

Customer: Deutsche Bahn AG, DB Cargo AG, Germany

Project tasks

  • Elicitation of the requirements from the driving service regulations
  • Elicitation of system requirements
  • Design and coordination of the test concept

Our Approach

PROSE has been assigned by DB Cargo to develop a requirements catalog for the perception system, which corresponds to the requirements catalog for ATO GoA2 and GoA4 + Remote Supervision & Control in freight transport. This requirements catalog will be used to evaluate a technology partner for the development, installation, integration, commissioning, certification and testing of such a perception solution. The tests for the one-year trial operation until 2025 will take place on the Dutch part of the Betuweroute (from Kijfhoek to Valburg).

Customer benefit

With the assignment of PROSE, the customer benefits from PROSE’s extensive experience in the fields of ATO, sensor technology and architectures. For this, profound technical knowledge, but also very good knowledge of the market, technology and railroad operations are indispensable. Thanks to PROSE’s structured approach, a well-founded result is ensured from a broad analysis on the technical possibilities and business implications of automation.

 

RAMS analysis of the Vivalto double-deck coaches

Customer: ATI (Ansaldo Breda, OFV and Magliola), Italy

End customer: Trenitalia, Italy

Project tasks

  • RAMS analysis guidelines
  • Safety analysis guidelines
  • RAMS analysis for the systems from ATI
  • Verification and validation of the systems from the sub suppliers
  • Documentation services
  • Protocol and test procedures
  • Study and analysis for CEI UNI 11170 application
  • RAMS analysis at coach level

Our Approach

PROSE elaborated the guidelines and the templates to realize the RAMS analysis. Furthermore, PROSE carried out a coach risk analysis and generated hazards (SFAS) relating to each system in the driver’s cab and the coaches.

Customer benefit

Thanks to PROSE‘s extensive experience with RAMS analyses and documentation services, the costumer was able to focus on the design. PROSE was responsible for the project management with the support of Ansaldo Breda’s RAMS office. Therefore, the approval of the RAMS documentation by Trenitalia was simplified and unproblematic. Furthermore, the Vivalto coaches are the first coaches to which CEI UNI 11170 was applied, which means that PROSE, ATI and Trenitalia can benefit from this experience for other applications in future projects.

 

Development of suspended monorail vehicles

Customer: Kiepe Electric GmbH, Germany

Project tasks

  • Mechanical design of carbody, vehicle interior and running gear
  • Mechanical system integration
  • Manufacturing supervision
  • Homologation management

Our Approach

In order to overcome the first challenge of creating the optimized vehicle for this particular application, PROSE developed a vehicle body that is constructed from aluminium extrusion profiles.
Moreover, the continuous low floor and wide-opening doors guarantee efficient passenger flow. The new vehicles for the Wuppertal suspension railway also offer high driver comfort.

Customer benefit

Given PROSE’s extensive experience in developing mainstream and special projects of all kinds, PROSE’s development team was able to successfully meet Kiepe Electric GmbH’s expectations. Furthermore, PROSE’s intercultural experience and capabilities are highly appreciated, playing a fundamental catalyst role in the current manufacture of the vehicles in Austria, Germany and
Spain.

 

Design of a 100% low-floor tram

Customer: CRRC Sifang Co Ltd, China

Project tasks

  • Tram concept
  • Design and development of bogie and carbody conceptual design and development
  • Electrical concept
  • Mechanical system integration

Our Approach

In cooperation with the client, PROSE developed the system specification for the whole tram and several of its components. One of the most challenging tasks in 100% low floor-trams is the design of the bogie, which had to be both compact and offer a quality ride. Single wheels were the solution.

Customer benefit

The newly designed 100% low-floor tram is a major upgrade of CRRC Sifang’s tram portfolio. The integration of CRRC Sifang’s production know-how and related processes into PROSE’s design work means lower production costs for CRRC Sifang.

 

Bogie engineering in Finland

Customer: Transtech Oy, Finland

Project tasks

  • Design and development of the bogie
  • Running gear design
  • Structural analysis
  • Simulation and analysis of running behaviour
  • Infrastructure test of structural stability and durability, and of load distribution
  • Detailed design for manufacturing

Our Approach

In this project, PROSE provided a full range of engineering services, including running-gear design for the whole vehicle, calculation of structural strength and durability, and detailed design. Simulation and analysis of running behaviour and measurements on Helsinki tram lines yielded important information on structural stability and durability and on load distribution.

Customer benefit

The result of the eight-month development period for the customer is a compact and robust powered bogie that is specifically suited to both Helsinki’s weather and the tram’s low-floor concept. In this process, the customer was able to concentrate fully on their core expertise, manufacturing, while PROSE took charge of developing all necessary documentation. As a corporately independent service provider, PROSE offered the customer system-oriented skills for the full life cycle of a rail vehicle.

Turnkey engineering for a freight wagon with sliding wall for high-speed operation

Customer: CRRC Jinan, China

Project tasks

  • Conception and development of the bogies, the car body structure and the sliding wall mechanism
  • Calculations of the running dynamics and the aerodynamics
  • Structural strength analyses
  • Preparation of component specifications, production drawings, assembly instructions and manuals
  • RAMS / LCC

Our Approach

PROSE performed the entire development process at several locations. PROSE can perform all services, e.g. engineering, design, analyses and calculations, project management etc., at several locations, which cooperate closely, but, of course, the internal communications between the various locations is also always ensured.
The manufacture and the approval tests were performed by the customer, but PROSE provided active support.

Customer benefit

Thanks to PROSE’s extensive experience with the various vehicle components at its various locations, PROSE can offer comprehensive turnkey engineering services. Our customer profits from PROSE’s know how due to the close cooperation and the mutual visits.

 

Adaption of German maglev train technology for operation in China

Customer: Shanghai Maglev Transportation Development Co. Ltd (SMTDC), China

Project tasks

  • Modification of the German maglev train TR08 in line with the requirements of a commercial operation in Shanghai
  • Support of reassembly of vehicles in Shanghai, commissioning and the start of operation
  • Realization of a maintenance optimization program with quality control processes
  • Performance of employees training in vehicle mechanics and on-site vehicle assembly

Our approach

PROSE supported the successful reassembly, commissioning and start of operation of the German maglev train TR08 for Shanghai Maglev Transportation Development Co. Ltd. Thereafter the vehicles were modified in line with the requirements of a commercial operation in Shanghai. A suitable, adjusted maintenance optimization program with quality control processes was developed and established. Training for maintenance personnel was carried out. Since then PROSE audits the world’s fastest train operation and its maintenance on a yearly basis.

Customer benefit

Successful operation of the maglev train in China was ensured because of PROSE’s yearly on-site inspections since 2011.

 

Development of a gauge-changing facility for operator MOB

Customer: Chemin de fer Montreux Oberland bernois MOB, Switzerland

Project tasks

  • Feasibility analysis
  • Mechanical and control engineering development
  • Detailed Manufacturing Design
  • Strength analysis
  • Support Approval

Our Approach

In cooperation with MOB, PROSE has developed the gauge-changing facility in several phases from a simple prototype to a complex series production system.

Customer benefit

From an early stage of the development of the gauge change system, PROSE supported MOB in approval issues. The complexity of the numerous interfaces between the gauge-changing facility and the vehicles, the infrastructure as well as the train protection systems of MOB and BLS were taken into account by PROSE through a close cooperation with the involved partners. From the conceptual design to the successful commissioning, MOB could be supported solutionoriented and target-oriented from one source.

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