Ensuring long-term availability of FLIRT1 EMUs
Customer: Hessische Landesbahn GmbH, Germany
Project tasks
- Obsolescence analysis
- Definition of replacement hardware architecture
- Software porting to new Compact-PCI platform
- Linux OS adaptation
- EMC planning (EN 50121-1)
- CSM analysis
- Requirement capture
- Test specification development
- Laboratory validation
- Prototype retrofit support (on-site)
- Creation of retrofit documentation
- Support during fleet rollout
Our approach
The FLIRT1 Electric Multiple Units (EMU) operated by Hessische Landesbahn GmbH were equipped with a Compact-PCI diagnostic computer that became obsolete and unavailable on the market.
The diagnostic computer records vehicle events and fault logs while displaying failure messages and troubleshooting guid-ance to the driver. Although the system is not safety-relevant, it is operationally essential for efficient maintenance and fleet availability.
Due to increasing component ageing and an expected rise in hardware failures, the obsolete unit had to be replaced by a successor model with full functional equivalence. The validated vehicle software architecture needed to remain unchanged, in order to classify the measure as maintenance acc. to (EU) 2016/797.
PROSE developed a risk-minimised hardware migration concept that preserved the existing vehicle software architecture.
We replaced the obsolete MEN Compact-PCI computer with a Duagon Compact-PCI successor model and ported the existing application software to the new platform. The Linux operating system environment was adapted to ensure identical system behaviour.
We implemented necessary interface adjustments without changing the validated vehicle software architecture. Our scope included:
- Porting and validation of the application software
- Creation of installation images
- Development of test specification
- Execution of a Common Safety Method (CSM) analysis
- Requirement capture documentation
- Preparation of an Electromagnetic Compatibility (EMC) plan according to EN 50121-1
- Laboratory validation and on-site prototype verification
We implemented and validated a prototype retrofit as the basis for a seamless fleet-wide rollout. In close collaboration with a specialised software partner, we ensured efficient implementation and full technical traceability.
Customer benefit
Hessische Landesbahn secured the long-term availability of its FLIRT1 fleet without functional changes or impact on the validated vehicle software architecture.
The reuse of the existing installation space reduced retrofit effort and vehicle downtime. The structured CSM process and comprehensive documentation ensured regulatory compliance and full technical traceability.
Through a structured engineering approach and comprehensive documentation, PROSE ensured regulatory compliance, tech-nical traceability and a reliable basis for long-term fleet opera-tion. Our independence from original equipment manufacturers enabled a pragmatic, lifecycle-oriented solution focused on availability and maintainability. A successfully validated prototype forms the basis for the fleet roll-out currently being prepared.
