Classification of the modifications and associated risks in accordance with RTE 49100
Preparation of an approval concept
Preparation of the documents to be presented to the FOT
Integration of FOT’s comments into the approval concept
Our Approach
PROSE managed the homologation process and supported the coordination between SBB Cargo and the Federal Office of Transport (FOT) to achieve the approval for the automatic coupler for commercial operation.
Customer benefit
The customer gains an overview of the valid regulations to be considered for the approval process with the FOT. Consequently, the authorities received a fast processing time and later the customer a lean, efficient verification and issue of the operating approval. PROSE has made a valuable, risk-minimising contribution to the “automatic couplers” project which is essential for the success of the strategic automation programme.
End customer: Montreux-Berner Oberland-Bahn (MOB), Switzerland
Project tasks
Composition of the modelling parameters
Creation of the MBS model for each wagon type
Implementation of the boundary conditions in the simulation environment
Carrying out and evaluating the simulations
Evaluation of the results
Documentation in a verification report
Our Approach
The computational verification of safety against derailment in twisted track curves was carried out in accordance with the BAV guideline based on EN14363:2016 using method 1 with test conditions adapted for metre gauge.
Customer benefit
Due to the broad experience of the experts at PROSE with the MBS modelling and simulation of rail vehicles and the performance of computational verifications, the derailment safety verification for the metre gauge vehicles could be carried out efficiently and in target-oriented manner.
End customer: Public transport company of Wuppertal, Germany
Project tasks
Development of the mechanical vehicle modules, i.e. car body and bogie
Project management
Definition and supervision of component tests
Homologation support
Our Approach
PROSE was responsible for the complete engineering of the main mechanical modules of the vehicle, which were the car body and the bogie.
Customer benefit
Given that PROSE was in charge of the vehicle development, customer VKD, who previously had been a component supplier, was able to expand its portfolio to the delivery of complete vehicles to the end customer. The know how of PROSE’s engineers in the field of turnkey engineering of complete vehicles, which is based on many years of experience with light-weight construction, was a basic condition for the successful results.
Gauging analysis of railway vehicles according to EN 15273
Gauging analysis of vehicles according to BOStrab
Calculation with special simulation programs cMotion or DIMA
Simulation of complex articulated vehicles, e.g. light rail vehicles
Consideration of national requirements (e.g. EBO resp. BOStrab in Germany or AB-EBV in Switzerland, etc.)
Consideration of requirements from network accesses (e.g. SBB I-20030 in Switzerland)
Gauging analysis of narrow-gauge vehicles according to AB-EBV
Analysis of special vehicles (e.g. suspended railways)
Our Approach
At first a verification concept is developed based on the customer’s specifications as well as requirements from infrastructure and standards. This can include the following, depending on the specific task:
Simple delta analysis (e.g. design adaptions or interoperability concerns)
Regular construction gauge calculation with static or kinematic methods
Calculation of gauging demand by means of accumulation of critical positions of the bogies in the track gauge, design tolerances, plays, etc. with distinction of random and non-random contributions
Simulations by means of the tool cMotion to model arbitrary vehicle configurations and track routing
Application of dynamic methods supported by simulations (e.g. swinging characteristics for suspended railways)
Development assisting analysis with continuous assessment and consulting
Validation via simulation or measurement (e.g. multi-body simulation or field test runs with attached blocks)
Compilation of input data, procedure and results to a report, ready to be submitted to Technical Authorities
Customer benefit
Due to the wide range of available methods and the long-standing expertise of the PROSE-experts arbitrary vehicles and requirements can be investigated. Potential problems will be anticipated and prevented. Manifested problems can be furthermore solved by experts of other disciplines. Additionally, a special focus on efficiency lies in our DNA as a service provider. Combined with a tailor-made concept for the customer and project this overall ensures that technical risks in development, homologation and operation as well as commercial overall efforts will be minimized.
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.
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.
Customer: Bombardier Transportation, Sweden
End customer: Delhi Metro Rail Corporation, India
Project tasks
Specification assessment of the equipment to be procured
Complete interior design of passenger interior and driver’s cab
Evaluation assistance of sub-suppliers bids
Overall assistance until delivery and assembly of the first trains
Our Approach
Bombardier was contracted to supply 424 metro trains to New Delhi’s metro corporation. PROSE was commissioned by Bombardier with the complete passenger interior and cab, excluding seats and floors.
Customer benefit
PROSE cooperated closely with Bombardier’s industrial design team and was able to meet customers’ expectations on the design elegance.
Low weight, high resistance to wear and high fire resistance requirements were met.
Project management of the buying process of the new rolling stock
Consideration of the client-specific requirements regarding marketing, finances, technique and company
External project management with PROSE acting as an agency
Our Approach
PROSE acted as an expert regarding the bogies and the technical documentation. Our experts were at customer ZB’s disposal to solve open issues, such as technical issues and the correct reference to pertinent standards, while ZB drafted procurement specifications. The service was rendered in close collaboration with ZB’s project management, which enabled receiving technical advice from PROSE within the tight project schedule.
Customer benefit
Cost-effective supply, operation and maintenance of the required rolling stock on the basis of clearly defined, contractual terms. Increased attractiveness due to a client-friendly utilization concept with a high availability.
Assessment of the functional requirements, quality and schedule
Development of technical solutions
Establishment and maintenance of a vehicle information system
Technical advice within the framework of the control group
Our approach
First, an assessment of the functional requirements, quality assurance plan and delivery schedule was carried out. Then the requirements for the asset management and reporting system were collected. The system was tendered and evaluated and a suitable supplier was selected. Along with the commissioning of the asset management and reporting systems, the control group that oversees the design, manufacture and commissioning as well as maintenance of the vehicles was commissioned, ensuring long-term value of the assets.
Customer benefit
Reduced risk for the competent authority when procuring the vehicles.
The authority can make correct and targeted decisions thanks to the technical solutions developed by PROSE.
