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Brake and thermal calculation locomotive Aaem841

Customer: Müller Technologie AG, Switzerland

Project tasks

  • Define and obtain input data
  • Brake calculation in TrainBrac
  • Thermal calculation in ANSYS
  • Specification and selection matrix for brake blocks

Our Approach

PROSE defines and procures the input data based on the relevant standards, which are required for the approval of the vehicle. Subsequently, the calculations were carried out and optimized so that the defined requirements were met. For this purpose, a brake calculation in TrainBrac was created in close coordination with the customer, as well as a thermal brake calculation in ANSYS, in order to prove the performance of the brake.  PROSE also contacted various brake block suppliers for possible linings on the basis of the specifications and calculation results and prepared a selection and decision matrix for Müller Technologie AG, including recommendations for the selection of a suitable lining.

Customer benefit

Thanks to PROSE’s expertise in this field, the customer receives documents to prove the performance of the modernised brake, which comply with the relevant standards and can thus be submitted 1:1 to the assessor/expert to achieve approval. Furthermore, the specification and pre-evaluation of the brake blocks material with decision support enables an efficient enquiry of possible suppliers.

Computational evidence of derailment safety for rack railway wagons

Customer: Matterhorn Gotthard Bahn AG, Switzerland

Project tasks

  • Compilation and preparation of parameters for modelling and simulation
  • Determination of the braking scenario to be considered
  • Creation of a multi-body simulation model (MBS model) of the rack railway container wagon to be investigated, as well as of the coupled train configuration
  • Execution and evaluation of the simulation
  • Documentation in an evidence report

Our Approach

At first, PROSE compiled all parameters required for modelling and simulation based on the customer’s data. Subsequently, the braking scenario relevant to the approval was determined and agreed upon with the customer. PROSE created the rack railway container wagon’s multi-body simulation model (MBS model) in the required modelling depth. The overall model of the train included a simplified MBS model of a flat wagon and the already at PROSE existing model of an HGe 4/4 II locomotive. PROSE simulated the most critical operational cases and documented the results and assessment of the simulations in an evidence report for the approval authority.

Customer benefit

The customer received an evidence report for the approval documentation, which clearly and comprehensibly documents the computational proof of the safety against the derailment of the rack railway container wagon. Based on the evidence, the customer received the approval for the wagon.

Engineering project IC2020-fleet

Customer: SBB, Switzerland

Project tasks

  • Creation of technical concepts
  • Preparation of the technical procurement documents BöB/VöB
  • Technical evaluation of suppliers
  • Preparation of the technical documentation for the retrofit
  • Accompanying prototype production on site in Olten
  • Updating commissioning instructions
  • Updating maintenance documents
  • Support in the approval process
  • Creation and monitoring of weight management

Our Approach

In a first step PROSE investigated the measures identified by SBB in the study phase and worked out the concept. PROSE prepared the technical procurement documents, such as specifications, technical requirement catalogues and interface drawings. The offers submitted by the potential suppliers were technically evaluated by PROSE and adjusted in the course of the technical negotiations. In the detailing phase, the system to be delivered was integrated into the vehicle documentation in cooperation with the suppliers who were awarded the contract by SBB.

Customer benefit

An international team of specialists from 4 countries is involved in the project at PROSE. Due to the project organisation PROSE is close to the customer SBB and therefore part of the overall project team. The creation of the production documents was done directly in the IT environment of SBB.

 

Mid-life maintenance of PRIMA BB27000 and BB37000 locomotives

Customer: AKIEM, France

Project tasks

  • Definition of the operations to be carried out for the mid-life maintenance of PRIMA locomotives
  • Identification of ways to increase reliability
  • Treatment of component obsolescence
  • List of changes that can be implemented in mid-life operation
  • Solutions for a hardware refresh
  • Definition of the industrialization process for mid-life
  • Analysis of the risks associated with the residual life of the equipment

Our Approach

PROSE has developed a high level of expertise in the PRIMA-E locomotive type, maintenance definition and reliability growth action plan.

Customer benefit

Thanks to its expertise in the field of rolling stock, over the entire life cycle, PROSE can offer its best services to accompany its customer through all the stages of the life of its locomotives.

Modernisation of 135 Interregio coaches for operator Flixtrain

Customer: Talbot Services GmbH, Germany

Project tasks

  • Creation of mechanical conversion
  • Preparation of circuit diagrams
  • Adaptation of air conditioning concept
  • Integration of new toilets
  • Integration of luggage racks
  • Certification support
  • Certification calculations
  • Mass management
  • Fire protection
  • Strength analysis

Our Approach

The Arkimbz, WRmbz, ABimdz, Bimdz and Bimz wagons were modernized, in following phases: starting-, initial-, planning, production- and execution phase. Finally the type test phase concluded the work.

Customer benefit

As a strategic engineering partner, PROSE was already able to convince the customer Flixtrain in the offer phase. When it came to the engineering work, you could rely on the skills of PROSE and thus focus on the conversion of the vehicles.

 

Technical documentation in the SJ X2000 refurbishment project

Customer: SJ AB, Sweden

Project tasks

  • Technical documentation
  • Translation
  • Coordination
  • Verification

Our Approach

PROSE contributed to the project by assisting in creation of new technical documents for the refurbished train fleet, as well as with translation, coordination, and internal review. Around 400 documents have been created for the project, and subsequently reviewed by the customer. PROSE’s team of technical writers contributed to update, and create new system manuals, maintenance manuals, spare parts catalogues, troubleshooting guides, diagnostic data sheets (DDS lists), component sheet, training documentation, etc.

Customer benefit

PROSE supported ABB and Stadler in the creation and translation of new technical documentation for SJ. The documentation was created in the office, combined with work in the depot, to make sure every product/function was clearly described. This helps operators to understand the updated products and systems, ensures correct use of the products and guarantees safety in maintenance work.

Refurbishment of X2000 class high speed trains

Customer: Stadler, Sweden

Project tasks

  • ​Overall project management
  • Electrical and mechanical engineering of the interior
  • RAMS
  • Approval management
  • Technical documentation

Our approach

During the tendering phase PROSE acts as consultant for Stadler. In the project, PROSE is responsible for technical project management, electrical and mechanical engineering, approval and RAMS. PROSE will also provide technical documentation services.

Customer benefit

Our customer benefits from PROSE’s great expertise in X2000 trains, as part of our team was already involved in the last modernisation 10 years ago. In addition, thanks to the modernisation, passengers will enjoy a completely new travel experience on board Sweden’s fastest trains – with new interiors, new seats and more efficient lighting. The availability of the trains will also be improved. The result is a train set that passengers will experience as completely new.

 

Audit of an ERTMS onboard system

Customer: Banedanmark (BDK), Denmark

Project tasks

  • Performance of the audit of the onboard projects of the Danish Signaling Program for the readiness for fitment
  • Assessment of the preparation for the installation phase of the vehicles in relation to:
    – Planning of the installation
    – Installation design
    – Prototype installation
    – Approval process
    – Assessment of different design issues

Our Approach

PROSE’s team of experts carried out this audit in less than three months; the audit covered the supplier Alstom, four railway operators, the national safety authority (Trafikstyrelsen), G-ISA and Banedanmark.

Customer benefit

Thanks to PROSE’s independent recommendations, our customer was able to optimize the current technical performance and to reduce the known risks.

Advice on the implementation of ECM Regulation 779

Customer: SBB CARGO, ECM2 strategic fleet management, Switzerland

Project tasks

  • Leadership coaching of the responsible head of strategic fleet management
  • Expert mentoring of the executing project employee
  • External workshop organisation for team development
  • Stakeholder management with management level, HRM, standards and regulatory bodies
  • Methodical tool development in the area of competence management
  • Strategic organisational development regarding structure and process organisation
  • Strategic knowledge management in quasi-governmental organisations

Our Approach

In a first step, the safety-relevant (ECM) activities were separated from the availability-relevant activities and documented in an external workshop. A competence matrix of the fleet management employees was created in several project work steps. PROSE then developed a target matrix on the basis of the content of the impending leap in standards from 2011/445 to 2019/779, whose delta on the actual situation can be used as the basis for strategic employee development and represents the comprehensive and detailed proof of competence in the forthcoming safety audits.

Customer benefit

The Head of Strategic Locomotive Fleet Management (ECM2) receives a comprehensive and detailed overview of the area of activity of his department and is in a position to document, reference and thus prove the ability to carry out these processes at any time and at the appropriate level in an audit-capable manner. Externally, this department achieves competence suited for the forthcoming re-certification to the new 2019/779 ordinance landscape. Internally, it serves as a practical example of the implementation capability within the framework of the CargoFit programme. Furthermore, process-related and competence oriented dependencies between the ECM2 activities will be established: safety, availability, system engineering and regulations are clearly documented and located.

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.

 

Expert opinion on fire safety for dual-purpose space – air box / shunter’s compartment

Customer: ZAUGG AG EGGIWIL, Switzerland

End customer: Trafikverket, Sweden

Project tasks

  • Standards research
  • Situation assessment from the user’s point of view
  • Preparation of an expert opinion

Our Approach

PROSE’s specialists prepare an expert opinion describing under which conditions the ZRR10000M snow cutter locomotive can be driven in reverse in working mode with the air box occupied. This opinion has been prepared to be submitted to the concerned Swedish authorities. The expert opinion is based on a simple FMEA on the subject of reversing with occupied the air-calming-room. Each case was considered, evaluated and, if necessary, operational or technical measures were defined.

Customer benefit

Since the view of this opinion was shared by the end customer and the licensing authority, ZAUGG has the legal certainty to offer the occupation of the air-calming-room and also knows the conditions for this.

 

Verification of train path price calculation

Project tasks

  • Testing of the vehicle-specific track price calculation
  • Examination according to BAV Document “Base price wear and tear in the track price 2017 – Instructions for the vehicle price determination”
  • Test in the function as recognised by the BAV independent test centre
  • Preparation of a test report and issuing a Test confirmation after successful Audit

Our approach

The track access charging scheme/calculation was tested with various vehicle specific data based on the “Base price wear and tear in the track price 2017 – Instructions for the vehicle price determination”. PROSE applied and received the official recognition by the BAV as independent test center after successful audit. Hence, PROSE is officially certified to perform track access charge analysis for specific vehicles and issue a test confirmations.

Customer benefit

The vehicle-specific calculation of vehicle prices by means of the results of multi-body simulations takes into account track-friendly construction methods of vehicles. This means that the vehicles can be operated with correspondingly lower train path prices.

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