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Project management and remote monitoring for a Proof of Concept SS-149

Customer: SBB, Switzerland

Project tasks

  • Project Management
  • Project Planning
  • Solution Architecture
  • Requirements Engineering
  • Sourcing
  • Supervision of the supplier’s Installation, Integration, and Commissioning
  • Data analysis and Reporting

Our approach

​Switzerland, as one of the first ETCS-only countries, required all active fleets to monitor malfunctioning Eurobalises, as per a national requirement (NNTR). With the TSI-2023 release, this NNTR had to be transferred and further developed into Subset–149, Online Monitoring System.

In December 2022, when the draft specification of the Subset–149, Online Monitoring System became available, PROSE was appointed by the rail infrastructure manager of Swiss Federal Railway to develop and conduct a Proof of Concept. The goal was to evaluate the suitability and completeness of the proposed protocol.

PROSE developed the system architecture and related requirements for an online monitoring of the MVB bus in the ETCS Onboard Unit (OBU) manufactured by Siemens and installed in a new Stadler FLIRT EMU owned and operated by Schweizerische Südostbahn. Railnova was identified as a suitable supplier and provided the related solution, both onboard (sniffer and gateway), and wayside. PROSE performed integration engineering as well as authorisation support.

Once the solution was in operation, PROSE closely monitored the wayside infrastructure and analysed the data and feedback to correct and improve the DRAFT Subset-149, contributing directly to its current maturity and reliability.

Customer benefit

With the assignment of PROSE, the customer benefits from the extensive experience of PROSE in the field of on-board signalling, ETCS and online monitoring, both wayside and onboard. PROSE’s combination of technical insight, hands-on experience, and understanding of the market landscape contributed to a solution that was both robust and fit-for-purpose. The customer could rely on PROSE to manage the project without needing to build up internal resources. In addition our independent advisory role ensured a neutral perspective, while maintaining alignment between the various stakeholders involved in the project.

 

  

Auxiliary bogie development for trams in workshop

Customer: Würzburger Straßenbahn GmbH, Germany

Project tasks

  • Auxiliary bogie development
  • 3D model (3D geometries for individual parts are part of the 3D model)
  • Combined welded assembly and machining drawings
  • Assembly drawing
  • Strength calculation results
  • Track guidance report

Our approach

PROSE has developed a workshop-compatible auxiliary bogie for temporarily relocating low-floor vehicles during maintenance work. The design is deliberately kept simple and allows the vehicles to be picked up without twisting. The aim was to create a solution that is functional, robust and at the same time designed in such a way that it can be manufactured and used independently by the operator. PROSE was responsible for the complete design – from the concept to the production-ready documents.

PROSE has a close relationship with Würzburger Straßenbahn GmbH (WSB), which has developed over the last few years through various successful co-operations. We were able to start designing the bogie quickly thanks to our familiarity with the technical requirements of the WSB fleet.

Our approach was to quickly determine the wheel diameter and by confirming the chosen parameters with the customer. This allowed us to move directly into engineering with a clear, shared understanding.

Throughout the 3.5-month design phase, we kept the process lean and efficient. Monthly status updates ensured the customer remained well-informed without requiring intensive involvement. Thanks to PROSE’s broad technical expertise, unnecessary iterations were avoided, contributing to a timely project delivery.

Customer benefit

Thanks to our close collaboration with the customer and our deep technical understanding, we were able to start development particularly quickly. The customer benefited from our in-depth expertise and understanding and was able to save a lot of time and effort. The solution was tailored precisely to the requirements of the workshop. The complete production-ready documentation, including 3D model, proof of strength and track guidance report, ensured rapid realisation. Thanks to our comprehensive and in-depth knowledge of industry standards, the conditions in the WSB workshop and close collaboration with the customer, we were able to anticipate challenges before they arose.

 

 

Operating load measurement and assessment of fracture mechanics

Customer: RAlpin AG, Switzerland

Project tasks

  • Operating load measurement
  • Wheelset shaft calculation
  • FE calculation
  • Fracture mechanics assessment

Our approach

The customer required two fracture mechanics analyses. On the one hand, the aim was to investigate what causes cracks to form on the back of the wheel flange and which factors contribute to crack growth. On the other hand, there was a need to provide a mathematical basis for the specified inspection interval for the wheelset shafts. Real operating load data should be used as the basis for the fracture mechanics investigations of PROSE.

PROSE carried out an unaccompanied measurement to record the operating loads on the routes travelled. For this purpose, a measuring system was installed directly on a bogie frame. This recorded the position of the vehicle combination over several days using an associated GPS antenna as well as the lateral and vertical acceleration and the rotational speed of the bogie using appropriate sensors. The measurement signals were continuously sent to a central storage unit via the mobile phone network. The real operating loads measured in this way formed the basis for the subsequent fracture mechanics tests.

The wheel disc cracks were investigated using two wheel types used by the customer. The load on these wheel types was simulated using MBS simulation based on the real load data.

To assess the fracture mechanics of the wheelset shafts, a wheelset shaft calculation according to EN13103-1 was carried out in a first step for orientation and to assess the general utilisation of the wheelset shaft. In a second step, cyclic crack propagation calculations were carried out at the critical shaft positions (positions with the highest bending stresses).

Customer benefit

Our fracture mechanics tests confirmed that the cracks in the wheel discs were not caused by braking behaviour or contact with the wheel control arm. Residual stresses were identified as a possible cause of the crack propagation. However, the fracture mechanics assessment of the wheelset shaft also confirmed that the existing test interval provides sufficient safety.

PROSE’s neutral and independent position and in-depth technical understanding gave the customer a solid starting point for further investigations. By utilising data from operational load measurements, the investigation could be tailored to real operating conditions, improving the quality of the results and increasing the client’s confidence in the findings. PROSE’s unique railway engineering expertise and extensive experience with rolling stock provides a bespoke, unbiased analysis that supports effective decision-making and long-term asset management.

 

 

Innovative service and operating concept for S-Bahn transport

Customer: Forchbahn AG, Switzerland

Project tasks

  • Scenario and variant supply and operating concept 2035+
  • Concept for on-demand operation with ATO
  • TARGET system architecture and gap analysis to the ACTUAL system landscape
  • Determination of requirements for later migration of the new vehicle

Our approach

PROSE supported Forchbahn in the tendering process for a new vehicle fleet. This also raised questions about the future service and operating concept of the S18 Zurich Stadelhofen – Esslingen line. In order to utilise the opportunity of a new vehicle fleet, PROSE developed various scenarios regarding vehicle lengths and the change in the current service concept through the use of automatically operated vehicles in the direction of on-demand operation at off-peak times. The scenarios were developed for different service levels, depending on the time horizon.

Based on the existing old vehicles, the timetables, the planned timetable and the frequency surveys of current operations, we analysed possible vehicle concepts and the resulting number of new vehicles. We specifically analysed the possibilities with long and short trains as well as the operational and technical reserves. We also developed a 2035+ service and operating concept using fully automated multiple units on the Forchbahn’s infrastructure. In addition to the migration and service steps in the introductory phase, this also included the concept for the introduction of on-demand operation during off-peak times. The tender process defined a target system architecture and vehicle requirements for future migration.

Customer benefit

Based on the actual data, PROSE conceptualised the target state and derived opportunities and risks for the respective thrusts in the service and operation. These were reflected in workshops with those responsible at Forchbahn. The results were integrated directly into the tender documents. This ensures that the vehicles are suitable for operation in the long term and that nothing stands in the way of the subsequent implementation of ATO-on-demand operation. PROSE’s knowledge helped Forchbahn make well-informed decisions early in the process, reducing future risks and supporting long-term operational efficiency.

 

 

Assessment of Tram Vehicle’s Compatibility with Planned Track Layouts

Customers: Würzburger Straßenbahn GmbH (WSB), Germany; HAVAG Hallesche Verkehrs-AG, Germany; Basler Verkehrs-Betriebe (BVB), Switzerland

Project tasks

  • Ensuring Tram Compatibility: Confirmation that existing tram vehicles can operate on planned track layouts
  • Track Layout Optimisation: Proposal of alternative track layouts that can be passed safely and without causing damage or derailment to the trams

Our approach

The track layouts of tram systems often have very individual characteristics due to the topography or the historical development of city centers. The tram vehicles need to be compatible for these specific infrastructure conditions. As a result, there is limited standardisation or harmonisation between vehicles and tracks in tram systems. Modern tram vehicles are often multi-articulated vehicles. Their vehicle length can extend over several track elements such as changes in horizontal curvature and changes in vertical gradient. In general, all vehicle sections are connected to each other in an almost torsionally rigid manner – apart from a small amount of flexibility in a few roof joints. Long articulated vehicles are therefore often sensitive to torsional loads, such as those that arise when combining small curve radii and large changes in vertical slope.

When planning new tram tracks, the question therefore regularly arises whether the existing vehicles can negotiate the newly planned route. The safety objectives are especially the safety against derailment and the damage-free bearing of the loads that occur. Furthermore, sufficient gaps between vehicle parts or the ground clearance underneath the vehicle can also be objectives.

PROSE investigates trafficability while using multi-body system (MBS) simulations, as they are used internationally during the development of rail vehicles. The simulation model contains the specific properties of the vehicles under assessment. This includes the overall vehicle concept, the detailed mass distribution as well as the individual running gears with their suspension levels, etc. Furthermore, the simulation model includes the track, which is characterised by the track layout to be tested, local track gauges and groove widths as well as any flat grooves. In addition, elastic track bed properties or geometrical track irregularities can be considered.

In the computer simulation, the vehicle models are moved over the planned tracks. The relevant combinations of boundary conditions such as the load, winter stiffening of the rubber springs, the wheel/rail profiles, the running speed etc. are considered. The simulation results are evaluated against assessment criteria from standards (e.g. safety against derailment) or evidence documents of the vehicle (e.g. bearable loads). If trafficability is not yet ensured, PROSE varies the track layout in a stepwise approach. For this purpose, previously agreed premises are followed which parameters, such as the superelevation or vertical slope etc., should be changed as a priority or must remain unchanged e.g. for urban planning reasons.

Customer benefit

An immediate benefit is the planning reliability that results from the proven trafficability of the new track. At the same time, the risk of late effects such as cracks occurring in the vehicle structure after the construction work has been completed is minimised.

 

Wear monitoring for meter gauge railway

Customer: Montreux-Oberland-Bahn (MOB), Switzerland

Project tasks

  • Project management
  • Concept development
  • System integration

Our approach

The Montreux Oberland Railway (MOB) was faced with a challenge when it was suddenly confronted with increased noise and heavy wear on the wheels and rails of a large number of vehicles in its fleet. Various vehicles showed unexpectedly high signs of wear.

PROSE carried out two days of acoustic measurements on a vehicle travelling on the MOB network. We used wireless microphones that were magnetically attached under the car body on each side of the train. The acoustic signals were sent wirelessly to a laptop inside the vehicle. With the help of special acoustic software, these acoustic signals were transferred from the time domain to the frequency domain in real time. Based on the amplitudes in certain frequencies, the problem of noise and wear in certain curves of the network could be localised. Additional measurements on the rails showed that the wheel flange lubrication on the rail was inadequate and was causing noise and wear. After manually lubricating around 10 curves on the 45 km network, the wear disappeared completely and the noise was reduced.

Customer benefit

The MOB had to reduce its services as the wear and noise pollution were no longer acceptable. After the problem was analysed and localised by PROSE-experts on the MOB network within a day of the measurement, noise and wear were reduced to a minimum and the MOB was able to resume regular operations.

 

  

Cybersecurity Awareness

Project tasks

  • PROSE presentation on the current state of the railway industry
  • PROSE presentation on the future development of the railway industry
  • In-depth discussion on TS 50701, security vs. safety and discussion on standards
  • Interactive brainstorming on the gap analysis
  • Consolidation of the results of the gap analysis and prioritisation
  • Analysis of the customer’s security documentation
  • Summary and definition of the next steps and goal

Our approach

The digital transformation of the rail industry is accelerating at an unprecedented pace. With increasing connectivity comes the urgent need to improve cybersecurity frameworks to ensure resilience against evolving threats. A recent industry workshop highlighted key findings on the current state of cybersecurity in railway systems and the expected regulatory changes that will shape the future.

Security in the railway sector has traditionally focused on protecting people and machines. However, cybersecurity has now become a critical factor in protecting IT systems, infrastructure and sensitive data. Despite their relevance, many existing railway standards provide only limited guidance on cybersecurity. Important standards such as EN 50126, EN 50716 and EN 50129 recognise security concerns but do not provide concrete measures. The IEC 62443 series, which emerged in the 2010s, has become a fundamental security framework, but its full integration into railway systems is still a work in progress.

A key challenge in cybersecurity is the human factor. Unclear role definitions in projects can lead to security risks – for example, through software updates that are implemented without sufficient validation and can compromise critical systems. Clear role definitions and structured safety processes are necessary to minimise such risks.

The future of railway safety will be shaped by new guidelines and harmonised standards designed to close existing safety gaps. Several regulatory developments will redefine safety requirements in the sector. The NIS 2 Directive obliges operators of critical infrastructure, including the railway industry, to take comprehensive cybersecurity measures. Companies in the supply chain will also have to prove their compliance in future.

The Cyber Resilience Act (CRA) places strict security requirements on manufacturers and suppliers of digital products, including railway technology. IEC 63452 is expected to become a global benchmark for cybersecurity in railway systems and combines elements from IEC 62443 and TS 50701 to create a standardised security framework. In addition, there is a trend towards common cybersecurity services – for example in the areas of authentication, logging and network security to ensure standardised protective measures for critical rail systems.

Customer benefit

Railway operators, manufacturers and suppliers must proactively adapt to these new regulations. Key recommendations include:

  • Identification and inventory of all assets (especially SW)
  • Conducting cybersecurity risk assessments to identify vulnerabilities
  • Establish clear security requirements for suppliers and ensure compliance throughout the value chain
  • Implementing security-by-design principles in the development of new products
  • Strengthen security incident response capabilities to effectively manage threats

By taking a proactive approach, the industry can ensure the safety, reliability and resilience of railway systems in an increasingly connected world.

  

Technical support and documentation for the modernisation of the EMU class 72

Customer: Alstom, Sweden

Project tasks

  • Requirements capture
  • Electrical system engineering
  • Technical writing

Our approach

PROSE provided technical support and documentation for the modernisation of the EMU vehicle class 72. An electrical systems engineer ensured that key upgrades—such as LED front lighting, USB ports, and interior lighting—met modern standards. In addition, two technical writers were assigned to update the existing technical documentation to reflect the improvements.

Our electrical systems engineering team took a methodical approach to ensure that all subsystems met functional requirements and complied with current standards and regulations. Our focus was to check subsystems such as LED front lights, USB contacts and passenger information systems (PIS). When we found gaps between existing components and required standards, we recommended improvements. Our thorough approach ensured that every aspect of the electrical system was optimised for modern operational efficiency and regulatory compliance.

Customer benefit

Our expertise allowed for a quick project start, helping the customer save valuable delivery time. ALSTOM also appreciated PROSE’s support on safety and regulatory matters, ensuring all requirements were met efficiently.

 

      

Finding potential suppliers for X10 bearing

Customer: Stadler Service Sweden AB, Sweden

Project tasks

  • Documentation review
  • Risk assessment
  • Specification update
  • Procurement management

Our approach

On behalf of Stadler Service AB, PROSE conducted a detailed preliminary study to identify reliable suppliers for an obsolete slewing ring bearing for the X10 trains. Given the challenges posed by the obsolescence of the existing components, this project aims to ensure sustainable sourcing solutions and support the long-term maintenance and availability of the train units.

In the first step, PROSE reviewed the customer’s existing relevant documentation and updated the requirement specifications according to the increased mechanical loads. In the second step, we identified and contacted several potential suppliers from within and outside Europe and discussed possible solutions in terms of both technical feasibility and cost efficiency.

Customer benefit

PROSE provided the client with a report containing a shortlist of potential suppliers and their respective offers. To assist the client in rapidly selecting a supplier, PROSE added its assessment of the suppliers and the corresponding offers as well as a subsequent recommendation.

 

  

Investigation on European EMU brake systems

Customer: leading international brake equipment manufacturer

Project tasks

  • Project management
  • Requirements capture
  • Concept development
  • System integration

Our approach

The project aimed to assist a leading international brake equipment manufacturer in navigating the complex landscape of European brake system regulations, generic design principles, and requirements for brake certification. The primary challenge was to provide the manufacturer with a consistent and clear understanding of these regulations to facilitate the development and certification of their brake systems for the European market. This support was crucial for ensuring compliance with stringent European safety standards and improving the manufacturer’s competitive edge in the international market.

Based on publicly available information and own experiences, PROSE provided a comprehensive investigation report with following main chapters:

  • European and American design philosophy and safety principles for emergency braking in EMU
  • Brake performance of current EMU train designs in Europe
  • Redundancy on emergency braking command and functions
  • Emergency Braking according EN 16185-1 and EN 15734-1
  • Brake system requirements for EMUs according to European TSI regulations
  • Brake system control signal according to EN 15611:2020

Customer benefit

As a result of this project, PROSE’s customer obtained an in-depth and detailed understanding of the general requirements and best practices associated with European EMU brake design. This comprehensive insight enabled the manufacturer to align their products with European standards, thereby enhancing their ability to meet certification requirements. Additionally, the detailed investigation report served as a valuable reference for the customer’s engineering and design teams, facilitating informed decision-making and innovation in brake system design. Overall, the project significantly boosted the customer’s capability to produce compliant, reliable, and competitive brake systems for the European rail market.

 

      

X61-X62 Delivery Projects last Technical Issues and Deviation Management

Customer: AB Transitio, Sweden

Project tasks

  • Resolve technical issues
  • Manage X61-X62 documentation
  • Support Rolling Stock Managers
  • Handle Regina, Itino, X61-X62, X11-14 deviations
  • Coordinate with stakeholders

Our approach

​As AB Transitio has successfully completed three key projects—X61 Västtrafik, X61 Östgötatrafiken, and X62 Norrtåg—PROSE is tasked with addressing and resolving all remaining technical and documentation issues, problems, and questions. Additionally, we are responsible for managing all deviations across AB Transitio’s six vehicle fleets, including Regina, X11-14, Itino, Coradia X61-X62, OUT, and Dosto ER1, ensuring that each is processed in accordance with AB Transitio’s established routines and policies.

Our approach involves providing the customer with comprehensive solutions to close all remaining technical and documentation issues for the three completed projects—X61 Västtrafik, X61 Östgötatrafiken, and X62 Norrtåg—by December 31, 2024. In addition, we are committed to supporting and enhancing AB Transitio’s deviation management process, ensuring that all deviations are properly addressed and implemented. We will also ensure that any change requests arising from these deviations are accompanied by the necessary information and documentation.

Customer benefit

AB Transitio had the opportunity to benefit from PROSE’s extensive knowledge and experience. By following this approach, the customer will be able to fully close all three projects—X61 Västtrafik, X61 Östgötatrafiken, and X62 Norrtåg—by the end of 2024, achieving 100% project completion. Additionally, they will benefit from an ongoing, quality-driven process that effectively manages all deviations, ensuring consistent and reliable handling of any issues that arise.

 

Validation Maintenace activities- Mälartåg

Customer: AB Transitio, Sweden

Project tasks

  • Validation of the maintenance process

Our approach

Transitio, as the owner, and MTR, as the operator of the Mälartåg trains, are responsible for validating the maintenance processes. This validation serves to complete the maintenance instructions and identify efficiency improvements in the maintenance processes. The train manufacturer Stadler is obliged to fulfil the contractually agreed specifications to ensure that maintenance is carried out to the highest standards.

The validation of the maintenance process is divided into five main phases:

  • Requirements planning and definition: This is where requirements are determined and clearly defined.
  • Definition of specifications and configurations: In this phase, the exact specifications and configurations are determined.
  • Verification: This phase serves to carefully review the previously defined specifications and configurations.
  • Utilisation: After the definition of requirements, design and qualification, which includes testing and commissioning, the utilisation phase follows. During this phase, continuous checks are made to ensure that the validated status is maintained. This is usually the longest phase and aims to ensure that the defined standards are continuously met throughout the entire service life.
  • Decommissioning: The final phase involves the orderly decommissioning of the system while maintaining the documented standards until the end.

The aim of this structured procedure is to maximise efficiency and safety.

Customer benefit

Monitoring the initial qualification of devices and compliance with defined processes during the utilisation phase are essential. This enables effective process verification, which allows potential deviations to be recognised at an early stage. In this way, preventive measures can be taken before deviations occur. This preventive monitoring and early correction make a significant contribution to maintaining the quality and reliability of operational processes.

 

     

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