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MBS-calculation safety against derailment of an electric track vehicle

Customer: ROBEL Bahnbaumaschinen, Germany

Project tasks

  • 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).

Automatic Train Operation

Customer: Swiss Federal Railways SBB, Infrastructure Division, Switzerland

Project tasks

  • Comprehensive consulting in the area of ATO (architectures and interfaces)
  • Consulting in the area of sensor technology (LiDAR, radar, camera) and their connections
  • Consulting in the area of remote control and the necessary technology and architecture
  • Consulting in the area of track monitoring and the necessary sensor technology for GoA3 and GoA4
  • Support in international committee work
  • Preparation of the feasibility study for the automation and remote control of a defined maintenance fleet including business case
  • Preparation of tender documents (dialog procedure)
  • Exchange with other programs and projec
  • Support in cooperation with other stakeholders (industry, railroads..)

Our Approach

The first objective is to develop a technical and commercial feasibility study for the automation of a defined maintenance fleet of several vehicles. This study includes all automation scenarios (GoA2, GoA3, GoA4 and remote control). The dimensions of cost, benefit, content and schedule are determined and as a result the tender documents are prepared.

Customer benefit

With the assignment of PROSE, the customer benefits from PROSE’s extensive experience in the fields of ATO, sensor technology and architectures. The customer does not need to build up project specific resources. The conceptual and technical consulting in the field of railroad automation provided by PROSE is used reliably, efficiently and target-oriented.

Rail grinding machine 2-24: Structural strength analysis

Customer: L&S Luddeneit und Scherf GmbH,  Germany

Project tasks

  • 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.

Simulation of derailment safety for an innovative tramway vehicle

Customer: Traila, Switzerland

Project tasks

  • Checking and compilation of the modeling parameters
  • Checking the implementation of the boundary conditions in the simulation environment
  • Evaluation of the results
  • Expert support and access to leading industry knowledge
  • Key supporter of technology development

Our Approach

Traila requested the support of PROSE to validate their simulation concepts and testing scenarios using the industry standard SIMPACK. In addition, PROSE was requested to validate the derailment safety analysis needed to successfully operate a test tram on the VBZ network. Traila developed a Matlab-based simulation model using Simscape MBD for system integration analysis purposes, as standard and detailed wheel-rail contact models for their application were not available at the time. Traila continues to invest in their simulation capabilities, to support the extensive development of the Traila technology.

Customer benefit

“Due to the extensive experience of the experts at PROSE with MBD modeling of rail vehicles, Traila was able to perform the derailment safety verification quickly, efficiently and successfully,” according to Dr. Tom Morris CEO of Traila. “Additionally, PROSE was quick to react and provide support when we needed it.”

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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