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Mechanical design and system integration

Customer: Various customers

Project tasks

  • Development projects:
    • Complete bogie design according to EN 15085
    • Complete car body design according to EN 15085
    • Interior and layout design
    • System integration (e.g. doors, brake system, HVAC, coupler etc.)
  • Vehicle modernisation projects:
    • Interior design
    • Layout concepts
    • System integration (e.g. ATC, infotainment system, magnetic rail brake, air conditioning system etc.)
  • Niche development projects (e.g. gauge changing and rack railway bogie, people mover or magnetic levitation systems etc.)
  • Structural bonding & welding competences:
    • Bonding according to DIN 6701-3 (A1) / EN 17460
    • Welding according to EN 15085-2 (CL 1)

Our Approach

Our focus is on the manufacturability and maintainability of a vehicle. We offer thought-through solutions in all our de-signs. We remain in direct exchange with our customer to ensure that the design process can be finished in a short time.

Customer benefit

With 3D model views we give visual answers to your ideas or thoughts. We have an agile way of working and can ensure that your feedback is shaping the visual idea and helping to complete it. Already in an early stage of the design process, the PROSE designer team ensures that the concept design is feasible. Our flexibility makes us respond to your requests at very short notice. We offer the complete batch of documentation for procurement and manufacturing.

 

Support with Assembly Line Layout – PRIMA Mid-Life Overhaul

Customer: AKIEM, France

Project tasks

  • Project Management
  • Concept & Development
  • Workshop Layout
  • Industrial engineering of mid-life overhaul of railway equipment

Our Approach

Akiem decided to transfer production to an industrial partner during the construction and commissioning of Akiem Technik’s site in Ostricourt as part of the PRIMA Mid-Life Overhaul (MLO) project. It is important that Akiem has an efficient industrial production facility in order to be able to ramp up production of mid-life operations on PRIMA locomotives in 2023 at the earliest. It is, therefore, necessary to set up an effective industrial production in the partner’s workshops.

We provided Akiem with our expertise and knowledge of workshop layout, and made sure they had the support needed at every stage of the process. The aim was to define all the production resources required for this modernisation project, and to ensure that the customer met their production rate targets. Keeping efficiency in the workshops and delivering productive solutions.

Customer benefit

PROSE has a long experience in assisting realisation and implementation of industrial layouts in the context of mid-life overhaul of rail vehicles. We can ensure the optimised flow of vehicles by developing the workload plan per workstation and the balancing of the workstations. The supply chain aspect and the management of logistics flows are integrated into the overall study. Making sure our customers get the best solution possible.

 

   

Assistance to the project owner for the renewal of contracts for the regional interurban public transport network

Customer: Région SUD , France

Project tasks

  • Project management
  • Provision of techno-commercial advice

Our Approach

Background: In the context of the evolution of the future scope of scheduled services, and considering the adoption of the Law of 24 December 2019, “Orientations des Mobilités”, the Transport Organizing Authority (AOT), the Southern Region defines its service offering.
The Region needed to strengthen these capacities in the face of the procedures for renewing contracts for the regional interurban public transport network in the Alpes de Haute-Provence region and the reorganisation of the Regional Express Lines in the areas concerned.

Approach: PROSE joined forces as a consortium to respond to this call for tenders. The consortium, led by the company Trans-missions, is made up of PROSE for its expertise in rolling stock, but also Tractebel for the infrastructure part.

Customer benefit

PROSE is supporting the South Region in the preparation, development and negotiation of a new operating agreement with SNCF Voyageurs. Our profound expertise in rolling stock empowers us to provide valuable advice for enhancing the terms of the operational monitoring contract. We focus on critical aspects such as reliability clauses, availability assurances, and proactive obsolescence monitoring. In the field of maintenance, PROSE’s expertise is made available for an accurate assessment of the advertised costs.

In the pursuit of the opening of regional passenger rail lines to competition, PROSE provides technical assistance on the new calls for tenders to come., Our technical expertise is poised to address critical areas, including:

  • ERTMS installation
  • Rolling stock maintenance
  • Sustainable development
  • Technical sizing of maintenance and siding sites, etc.

 

   

Re-design studies of the PRIMA BB27000 and BB37000 locomotives

Customer: AKIEM, France

Project tasks

  • Pre-studies (feasibility study and budget estimate on different topics)
  • Electrical and mechanical integration studies
  • Replacement of the headlights with LED headlights
  • Integration of a socket with USB ports in the driver’s cab.
  • Modification of existing circuit diagrams
  • Design of integration plans and schemes
  • Creation of an operating and an assembly manual
  • Budget estimate to modify the entire PRIMA fleet of AKIEM
  • Supply of prototype parts and support for its integration
  • Carrying out the procedure and the test report
  • Updating of documents after the integration of the prototype and the realisation of tests, if necessary
  • Provision of the purchase specifications of the parts for the series
  • Impact assessment of the amendment

Our Approach

To carry out all pre-studies and studies, PROSE has set up an internal organisation:

  • Project Manager / Coordinator
  • Electrical Engineers
  • Mechanical Design Engineer
  • Expert in change impact analysis

PROSE worked in collaboration with AKIEM to provide the best possible solution in the shortest possible lead time.

Customer benefit

Thanks to our expertise in the field of rolling stock and our engineering department with its various competence centres, PROSE was able to offer our best services to propose modifications and carry out innovations on the locomotives.

 

Wheelset torsional vibration

Customer: Various customers

Project tasks

  • Basic assessment of the vehicle’s wheelset torsional dynamics
  • Analytical estimation for dimensioning the wheelset shaft and, if necessary, other components
  • Multibody simulations for a more detailed analysis for optimization
  • Consulting and support for homologation measurements and support for documentation for homologation.

Our Approach

PROSE accompanies the entire, or single sections of the process chain, from the pre-design of the wheelset shaft over the optimization of the mechanical components up to the execution
of the homologation measurements for the determination of the maximum, dynamic torsional moment. By means of analytical and conceptual investigations, a fundamental assessment of the wheelset torsional dynamics of the vehicle is already carried out in advance, taking into account the dimensioning of the wheelset, the powertrain configuration and drive systems. Based on the preliminary investigations, in-depth analyses are carried out in consultation with the customer using multibody simulation models. On the one hand, these investigations limit
the maximum dynamic torsional moment to be expected, indicate the component loads to be expected and, at the same time, describe other dynamic properties of the driveline. Considering the existing driveline configuration, its design properties are optimized in such a way that the mechanical damping of the first torsional eigenmode of the wheelset is increased, thereby reducing the maximum dynamic torsional moment. The results of the analyses provide relevant information for the system analysis required for certification, which describes the wheelset torsional dynamics of the vehicle. In addition, the analyses are used to determine the vehicle configurations critical for planning and performing the homologation measurements. Finally, the maximum dynamic torsional moment is determined with metrological tests on the vehicle.

Customer benefit

The analyses carried out help the customer to minimize risks in the approval of the wheelsets. The preliminary investigations enable realistic time and cost planning up to the approval of
the wheelsets. The in-depth analyses and component optimizations reduce the stresses caused by torsional vibrations and prevent damage to safety-relevant components during operation. Finally, the identification of critical operating conditions significantly reduces and secures the scope of the homologation measurement.

 

Centralising the ICN tilting train maintenance – Variant study for maintenance work in a short shop

Customer: SBB Passenger Traffic, Switzerland

Project tasks

  • Project management
  • Variant assessment
  • Operating and production concept
  • Compilation of profitability calculation

Our Approach

Together with various SBB organisations and several specialist planners (L2A Architekten AG, Technisches Büro K.N.O.L.L. GmbH, Wiederkehr und Villiger AG and Fahrgrund AG), 12 variants were developed in the greater Biel area and evaluated operationally, technically, and economically. Planning documents, a cost estimate, a possible schedule, and the corresponding application documentation for the decision-making process within SBB were prepared for the best variant. In addition, a recommendation was made for further procedures, including the risk assessment for the subsequent phases.

Customer benefit

With the wealth of experience of the people involved, the possibilities at the Biel site could be quickly and efficiently identified and evaluated. The option of additional roof work was subsequently integrated due to the consideration of the entire production concept.

 

Strength analysis (FEA simulation)

Customer: various customers

Project tasks

Development of verification concepts and load assumptions as well as performance of calculations and simulations for:

  • Car bodies according to e.g. EN 12663
  • Bogies and wheelsets according to e.g. EN 13749, EN 13261
  • Streetcars and metros according to VDV 152
  • Attachment parts according to EN 61373
  • General load assumptions from calculations, measurements and simulations for e.g. special vehicles

Static, fatigue and time strength assessment:

  • Base material and weld seams according to FKM Guideline
  • Fatigue of steel according to Eurocode 3 DIN EN 1993-1-9 and BS 7608
  • Weld seam evaluation according to DVS 1612 / DVS 1608 and IIW recommendation
  • Screw connection according to DIN 25202:1-6, VDI 2230 and Eurocode 3 DIN EN 1993-1-8
  • Cylindrical helical spring according to EN 13906

Further analyses:

  • Nonlinear and crash analyses
  • Heat transfer analyses
  • Topological optimizations
  • Eigenvalue analyses
  • Stability analyses
  • Damage analyses and repair solutions

Our Approach

Depending on the customer’s specifications, PROSE carries out strength analyses in parallel with the design in its own development team or works directly with the customer’s team. PROSE covers the entire range of the analysis from the development of the load assumptions to the modelling to the efficient execution of the calculations and simulations as well as the evaluation of the results. Based on the strength analyses, PROSE can prepare test specifications for structural tests, accompany tests and, if required, validate the strength model with the evaluation. PROSE engineers have interdisciplinary know-how also in non-railway specific problems. Furthermore, PROSE also takes over the coaching of simulation processes and supports as a neutral consultant.

Customer benefit

Through the early use of strength analyses in the design process, weak points are identified and eliminated at an early stage, costly test series are avoided and the quality of the product is decisively improved. In addition to a qualified calculation, PROSE attaches great importance to the interpretation and presentation of the results required for the customer, including explanations and, if necessary, documentation relevant for approval. Due to its great flexibility, PROSE can respond to customer requests at very short notice

        

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.

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

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.

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