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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 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.

 

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.

Expert assessment running dynamics of TramTrains

Customer: TÜV Rheinland, Germany

End customer: STADLER RAIL VALENCIA S.A.U., Spain

Project tasks

  • Creation and structuring of the verifications (in Karlsruhe for the EBO area, in Chemnitz for the EBO and BOStrab areas)
  • Monitoring of experiments
  • Expert assessment for the approval of the two tram trains according to §32 EBO in Germany (driving technology completely according to EN 14363) and in Chemnitz also according to BOStrab

Our Approach

In a first phase, the coordination of processes and the scope of approval with the competent authorities is therefore essential. This often also influences the duration of the approval process, the costs, and the risks. PROSE developed the verification concept together with the manufacturer. In a second phase, the agreed reports to provide evidence were prepared. This was done with the involvement of the manufacturer and the testing authorities. In the third phase these reports were assessed and finally the expert report was prepared

Customer benefit

The wide experience of the experts at PROSE lead to an optimal definition of processes and requirements from the beginning. This reduced process risks right from the beginning and ensured adequate stakeholder management. The active process design lead to a solid and target-oriented verification process involving authorities, manufacturers, test laboratories and other third parties. The customers also appreciated the swift feedback on the submitted documents and, in case of problems, the support in finding solutions.

Expert reports on running dynamics

Customer: Various customers

Project tasks

  • Driving evaluation of all types of railway vehicles including specialties such as two-way vehicles and tram trains
  • Driving evaluation and assessment of work and stability of crane vehicles, lifting platforms, excavators, bridge soffit devices, etc.
  • Accompaniment of speed increases of existing vehicles
  • Driving assessment on assignment of network access points
  • Extension of approval in State A based on approval in State B

Our Approach

In a first phase, the processes and the scope of approval is negotiated with the responsible authorities. This is essential as it dominates the time and costs of the approval process as well as the risks involved. In a second phase, the agreed evidence is then provided (simulations and tests performed) and evaluated. In the third phase, the expert report is prepared based on these reports on simulations and tests and – if required – represented before the authorities.

Customer benefit

The vast experience of PROSE’s experts leads to an optimal definition of processes and requirements from the beginning. Customers also appreciate the swift feedback on the submitted documents and, in case of problems, the support in finding solutions. Especially in countries without formal recognition of experts, it
is important that the customer can expect that the expert opinion will be accepted by the regulatory authority. The broad acceptance of PROSE’s experts ensures this.

Expert report on running dynamics of an Atlas road-railexcavator

Customer: Atlas GmbH, Germany

Project tasks

  • Structuring of approval requirements and proofs
  • One-time monitoring of tests for the first vehicle variant
  • Expert assessment for the approval of the road-rail-excavation according to §32 EBO in Germany (running dynamics incl. safety against derailment and stability criteria)

Our Approach

PROSE has developed the verification concept together with the manufacturer, witnessed some selected type tests and prepared the expert report based on the basis of the reports on calculations and tests provided.

Customer benefit

The wide experience of the experts at PROSE leads to an optimal definition of processes and requirements from the beginning. The active process design leads to a solid and target-oriented verification process involving authorities, manufacturers, test centers and other third parties. The customers also appreciate the quick feedback on the submitted documents and, in case of problems, the support in finding solutions.

 

Support for the approval of an automatic coupler

Customer: SBB Cargo, Switzerland

Project tasks

  • Analysis and description of the modifications
  • Formulation of the proposed modifications
  • 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.

Multi-body simulation for providing evidence for safety against derailment for a metre gauge vehicle

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

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.

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