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Auditing vehicle maintenance

Customer: Appenzeller Bahnen, Switzerland

Project tasks

  • Organisation
  • Workshop inspection
  • Consolidation
  • Report

Our Approach

PROSE implemented the maintenance audit in four sections: The content and objective of the first part was the deductive immersion in the maintenance organisation, starting from the strategy, the annual report on the structural and process organisation, the basic compatibility assessment of functional process organisations and the cooperation and division of labour between the different workshops. In the second part of this audit, two workshops were visited and their work was evaluated with regard to the knowledge gained in the first part and any gaps and/or suggestions for improvement were collected. Finally, the collected impressions were summarised and reflected upon and located with the client. The final report documented the result of the external view and provided information on the development status of vehicle maintenance.

Customer benefit

During the four abovementioned inspections, the Appenzeller Bahnen and their maintenance team received valuable feedback on their processes, on the organisation of procedures and processes, as well as on the status of their documentation. A number of suggestions for improvement were gratefully received and implemented as soon as possible.

 

ATO GoA2 over ETCS and national Class B Systems Requirements Capture and Approval Risks Analysis

Customer: Nederlandse Spoorwegen, Netherlands

Project tasks

  • Vehicle Authorisation Management and Strategy
  • Operational concepts
  • Automatic Train Operation (ATO)
  • Requirements Analysis
  • Roll out Concept

Our Approach

PROSE analysed possible risks in the homologation and deployment of ATO GoA2 over ATB via STM-Module and analysed the requirements for ATO out of the TSI CCS and TSI OPE. Through analysing project risks concerning existing standards, approval processes and the target architecture, PROSE provided an in-depth analysis proposing a vehicle authorisation approach that covers the overall system level and the changes to the technical and operational subsystems. Besides an approval concept, PROSE provided a roll-out approach for ATO that mitigates safety risks related to Human-Machine-Interface.

Customer benefit

NS benefits from PROSE’s in-depth analysis and concept as an independent second opinion and the adaptation of experiences gained in other ATO projects. Due to the extensive overall system knowledge, PROSE was able to consider all relevant subsystems of railway operation and technology and deliver an NS-aligned approach.

Approval support snow blower zb

Customer: ZAUGG AG Eggiwil, Switzerland

Project tasks

  • Proof of derailment, restriction and strength
  • Expert reports on fire protection, derailment and restriction

Our Approach

The AB-EBV requires a proof of compliance with the reference line. For this proof, PROSE has prepared a restriction calculation according to EN 15273-2:2013 as well as an independent expert report. The front and side windows are glued to the cabin of the snow blower. ZAUGG is not certified according to DIN 6701, but will have the bonding work carried out by an external company. PROSE has been commissioned to provide proof of strength for the two A1 bondings. In addition, the AB-EBV requires an expert report on the fire protection concept, which has been prepared by PROSE experts. PROSE has also provided the proof of derailment safety according to the BAV guideline “Nachweis sicheres Fahrverhalten Meterspur-, Spezialspur- und Zahnradbahnen”, as well as an independent expert report.

Customer benefit

PROSE’s expertise in the topics of verification as well as its comprehensive knowledge made it possible to use independent experts for the preparation of the expert report. For this reason, time was saved and ZAUGG was able to submit the required documents to the BAV on time.

Fire protection monitoring technology IC 2000

Customer: SBB, Switzerland

Project tasks

  • Risk analysis for fire protection of the technical components
  • Conceptual design of fire protection monitoring
  • Integration concepts for the different vehicles
  • Electrical integration
  • Complete installation and maintenance documentation
  • Verification documents for approval

Our Approach

Beforehand, PROSE had already developed an initial concept for the cable routing and carried out a risk analysis of the affected components. Together with the component supplier, PROSE then developed a detailed concept for the mechanical integration of the LHD cable and the other components required for monitoring in the vehicles. After the conversion of the first prototypes, the complete documentation as well as the proofs for the approval were prepared by PROSE.

Customer benefit

In particular, the customer was able to benefit from the comprehensive know-how of PROSE’s experts, who were able to comprehensively narrow down the complex topic of fire protection monitoring and its integration based on their knowledge of the vehicles. Due to the intensive support of the workshop, questions could be clarified immediately and thus the target dates could be optimally met.

Development Connection Magnetic Rail Brake Locomotive Gmf 4/4

Customer: Rhätische Bahn, Switzerland

Project tasks

  • Geometric investigations
  • Risk analysis with expert opinion
  • Rough and detailed concept
  • Clearance verification (gauging)
  • Strength verification
  • Approval support

Our Approach

In the first phase, PROSE, as the developer of the motor bogie, was commissioned by the RhB with a geometric investigation, which showed that the possibility of slippage of the MTR in unfavourable situations could not be excluded. In a second phase, PROSE prepared an expert opinion describing under which conditions (operational, system characteristics, etc.) safe operation with the four service traction units Gmf 4/4 can be guaranteed until the completion of the conversion. This statement is intended as a basis for an RhB-internal risk assessment. In the last phase, PROSE developed a rough and detailed concept with gauging (clearance) and strength verification for a cross connection of the MTR arranged on both sides of the engine bogie of the locomotive Gmf 4/4. In addition, PROSE supported the customer in preparing the documents relevant for approval according to the regulation RTE 49100.

Customer benefit

Due to the detailed system knowledge of the bogie and the contribution of expertise in connection with the safety-relevant operation, the customer was able to remedy the malfunction with the most efficient measures possible. PROSE’s competence in vehicle authorisation also helped the client to submit the required documents to the Federal Office of Transport FOT in due time.

Leadership Coaching and Strategy Consulting Digital Interlocking

Customer: SBB Infrastructure, Switzerland

Project tasks

  • Leadership Coaching
  • Strategy Consulting
  • Stakeholder Management

Our Approach

PROSE is carrying out the leadership coaching and strategy consulting for the SBB project manager “EESA 3.1 – Industrialised Rollout”. The leadership coaching was conducted between the poles of the rollout implementation, defined in the directional decision, and the call for tenders, which had to be prepared concurrently. On the one hand, the time constraints associated with the implementation were addressed, which led to good progress in the conceptual and content-related work. On the other hand, the strategy consultation dealt with prioritising the tender contents, whereby the implementation of innovations and the inclusion of essential rollout requirements were subordinated to securing the contract.

Customer benefit

In addition to more minor and continuous further developments of concepts, significant successes were also achieved in some areas. From a project management perspective, the following topics deserve special attention:

  • Publication of EULYNX Baseline 4.1 with the necessary adaptations for Switzerland.
  • Concluded procurement of a proof-of-concept platform for the Object Controller to demonstrate software separation, security features and a reference implementation of the Rail Safe Transport Application (RaST).
  • Results of the first iteration in the study, “Expandability using the example of the Dagmersellen – Emmenbrücke line”, showing a cost-saving potential between 50% and 75%.
  • Make-or-buy workshop with infrastructure management

Finite element analysis and strength verification for folding seats in the AS coach

Customer: FAINSA, Spain

Project tasks

  • Strength calculation of the folding seats
  • Proposals for optimisation and recalculation of the design
  • Final verification calculation with final report

Our Approach

In order to be able to implement the project, CAD 3D models of three seat types were provided by the customer. The models were read into the FEA software by PROSE and analysed. Based on the results and in close cooperation with the customer, various optimisations of the designs were made. These optimisations were recalculated and, if necessary, further improved in the construction. After the optimised designs met the requirements of UIC566, a final report could be prepared with the proof of strength requested by SBB. This report was required as an initial type test document and also served the end customer as a verification document for the seats in order to obtain approval for the passenger coaches.

Customer benefit

Our engineering services provide the customer with optimised seat designs whose strength can be verified. The knowledge of the approval processes and the end customer-specific requirements enable PROSE to create “approval-proof” documents that can be accepted by the end customer. Our knowledge of local conditions and experience as an internationally active company enables us to build a technical and formal bridge between the seat supplier and the end customer.

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.

Fire protection, LCC and FMECA for water cannons

Customer: Vogt AG, Switzerland

Project tasks

  • Acquisition of input data
  • Fire protection analysis
  • LCC analysis
  • Failure mode effects and criticality analysis (FMECA)

Our Approach

PROSE has created the fire protection analysis and the corresponding fire protection material list for VOGT. Furthermore, input data were collected for LCC and FMECA analyses. These data were inserted in the project-specific templates. As a result, documents were created according to the specifications of the end customer.

Customer benefit

PROSE has taken responsibility for VOGT to provide the correct input data for Fire Protection, LCC, and FMEC analyses and to create the documents by the end-customer accepted quality. This relieved VOGT of tasks that are outside their core business.

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.

Alternative forms of operation for the Appenzellers Rack railways

Customer: INFRAS, Switzerland

End customer: Canton of Appenzell A.Rh. and St. Gallen

Project tasks

  • Actual state analysis and screening of the available information including inspection of the three railway lines
  • Description of the state of the art in the market
  • Investigation of Automation possibilities
  • Development of a cost and benefit analysis
  • Creation of a final report including evaluation and recommendation for all three railway

Our Approach

As a first step a state analysis and screening of the available information including inspection of the three railway lines was carried out. Then a target system architecture was described using state of the art available technology. Various automation possibilities were developed and assessed. On top a cost and benefit analysis was carried out. All findings were collected in the final report including evaluation and recommendation for all three railways.

Customer benefit

Thanks to PROSE’s structured approach INFRAS received a well-founded result from a broad diversified analysis of the technical possibilities and economic effects of automation of the railway operation of the three lines. During the project the client received an overview of the possibilities as well as of the current state of the art on the subject of automated and autonomous driving operation. PROSE therefore develops a concrete recommendation and the magnitude of the necessary investments in the introduction of automated railway operations.

 

 

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.

 

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