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Strength verification of bonded joints IC Bt

Customer: SBB, Switzerland

Project tasks

  • 3D FE modelling
  • Derivation of loads
  • Definition of load cases
  • Evaluation of load cases
  • Verification report
  • Adhesive drawings

Our Approach

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.

 

SAMMS-t710: Structural strength analysis

Customer: L&S Luddeneit und Scherf GmbH, Germany

Project tasks

  • 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.

Interior design of Delhi Metro

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.

Support for project management in procuring interregional rolling stock

Customer: zb Zentralbahn AG, Switzerland

Project tasks

  • 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.

 

ZPS vehicle expert for the electric network “Saar-RB”

Customer: ZPS – Zweckverband Personennahverkehr Saarland, Germany;
SPNV Nord – Zweckverband Schienenpersonennahverkehr Rheinland-Pfalz Nord, Germany;
SPNV Süd – Zweckverband Schienenpersonennahverkehr Rheinland-Pfalz Süd, Germany

Project tasks

  • 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.

   

Load assumptions and strength analysis of tramway track components

Customer: Würzburger Straßenbahn GmbH, KÜNSTLER Bahntechnik GmbH, Germany

Project tasks

  • Clarification of the intended track layout, speed restrictions and wheel/rail profile conditions
  • Setup of appropriate multi body system (MBS) models of the tracks including the cross-sections of the switch blades as well as three types of existing tram vehicles
  • Conduction of a variation of MBS simulation runs and extraction of loads acting on track components like e.g. rails, switch tongues; setup of related load assumptions
  • Setup of a finite element model (FEM) e.g. of the switch tongues and the surrounding structure
  • Fatigue strength assessment of the track component while applying the loads as gained from the MBS simulations
  • Proposals of design improvements regarding the strength
  • Meter gauge tram application
  • Tracks including deep grooved switches

Our Approach

Running dynamics simulations have been performed to determine the wheel/rail loads, which are acting on the related track components. The specific conditions of WSB have been considered while conducting multi body system (MBS) simulations for all three types of vehicles in all relevant directions of travel through the triangular joint “Sanderring” as well as the tracks in front of the central railway station. As a result, load assumptions for the track components under assessment (e.g. switch tongues) have been extracted from the MBS simulations. A finite element model (FEM) of the component and the surrounding structure was set up. The wheel/rail load assumptions as derived from the MBS simulations have been applied to the FEM model. A fatigue assessment was conducted while analyzing the strength amplitude as deriving from the maximum strength. Based on the FEM results, specific design adjustments have been recommended to improve the strength.

Customer benefit

One major benefit is the minimization of the risk e.g. of occurrence of cracks. This is especially important, as new tram vehicles by tendency come along with higher axle loads and are thus more demanding regarding the strength of track components. Another benefit is the reusability of the load assumptions as well as the strength analysis for future tenders of similar track layouts under comparable conditions. Two of the three MBS vehicle models have already been setup in a former project for WSB. Thus, the benefit of reusability without initial modelling efforts was already used in this project.

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