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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.

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 optimisation, 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 optimisation 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 modernisation 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.

 

Research project for an innovative concrete sleeper

Customer: Swiss Federal Office for the Environment, Switzerland

Project tasks

  • Experimental modal analysis on different concrete sleepers
  • Computational modal analysis FEM
  • Measurements in specially built test track
  • Measurements of TOR and sound radiation
  • Design and analysis of two sleeper types
  • Manufacture of sleepers by project partners

Our Approach

The new concrete sleepers were developed in cooperation with the Swiss concrete element manufacturer Vigier Rail. The existing sleeper types were first examined and analyzed using measurement technology and the parameters influencing the acoustics were analyzed.

Customer benefit

With this research project on an essential element of the track superstructure, PROSE wants to advance the industry – with less noise and simultaneously low wear and tear or lower life cycle costs. This benefit both the affected residents and the infrastructure contractors.

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.

 

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 engineers, at that time as members of ThyssenKrupp Transrapid, 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. Until 2019 PROSE audited 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.

Turnkey Engineering for snowblower

Customer: ZAUGG AG EGGIWIL, Switzerland

Project tasks

  • System engineering incl. consulting and weight management
  • Monitoring and elaboration of risk assessment according to CE
  • 3D design of complex devices incl. creation of production documents
  • FEM analysis of the supporting Structure

Our Approach

PROSE received the order from ZAUGG to realize, together with ZAUGG’s engineers, the complete mechanical engineering of the main assemblies, base frame and blower mechanics. The placement of the diesel units and hydraulic components were defined in close cooperation. The factors to be taken into account for the clearance gauge were also specified.

Customer benefit

Due to PROSE’s extensive system know-how, ZAUGG received all necessary documents to manufacture, commission and approve the snow blower on their own. With the technical competence in the development of complete vehicles, based on the long experience of PROSE engineers in lightweight construction, ZAUGG could successfully deliver the snow blower as a general contractor.

 

Definition of a vehicle authorisation strategy for a driver advisor system

Customer: KNORR BREMSE, Switzerland

Project tasks

  • Homologation strategy
  • Operational applicability
  • Human factor limitations

Our Approach

PROSE conducted an expertise on different topics. The aim of the PROSE homologation consulting was to prepare an argumentative concept on the legal situation relevant to homologation, as well as a description of the scope and content of the necessary notification to BAV (Bundesamt für Verkehr).

Customer benefit

KNORR BREMSE received a thorough expertise on the homologation imperative with regards to implementation of the driver advisor system in shunting and main line operation,  operational as well as human factors in and around the utilization a video camera system with artificial intelligence.

 

Setting the standards framework for maintenance

Customer: Knorr-Bremse Rail Systems, Switzerland and Rail Vision, Israel

Project tasks

  • Definition of requirements management
  • Creation of a standardisation framework
  • Delimitation of life cycle phase
  • Obsolescence management
  • RAMS & LCC Management

Our Approach

PROSE supports Knorr-Bremse and Rail Vision within their endeavor and defines the normative maintenance framework that builds the basis for a life cycle service contract upon installation of the electro-optic sensor systems.

Customer benefit

After prototype testing is successfully completed at the end of the first quarter of 2021, the partners will examine further business opportunities for integrating these systems into rail freight vehicles.

Feasibility study on driverless train operation (DTO)

Customer: BLT Transport AG, Switzerland

Project tasks

  • Overall observation of the market
  • Detailed description of the planned infrastructure
  • Analysis of standards, technology and safety
  • Conclusion of asset of proposed measures of realisation – in coordination with FOT

Our Approach

During the first phase, a market overview was carried out together with a detailed description of the planned infrastructure – which ensured the achievement of the range required. The next step was creating the additional depth required by using standard technology and safety analyses. After consolidation, various variants were developed and evaluated during the feasibility phase. In coordination with the Federal Office of Transport (FOT), the best variant was selected and subsequently specified by proposed implementation measures

Customer benefit

Thanks to PROSE’s structured approach, BLT received a well-founded result based on a diversified analysis. During the realisation of the project, BLT already received an overview of the current state of the art autonomous transport systems and of present projects. In the end PROSE developed a coordinated proposal for a step by step introduction of autonomous operation, as well as further steps required for implementation, which were coordinated with the FOT.

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