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Tag: Mechanical vehicle & systems engineering

Mechanical vehicle & systems engineering – Our solutions

Blue and white Västtrafik tram on route 3 to Kålltorp travelling through a historic city street in Gothenburg, Sweden.

Reverse engineering of new gears and housing for trams

Customer: Västtrafik AB, Sweden

Project tasks

  • Measuring of the gearbox housing
  • 3D modelling and technical drawings
  • Material definition
  • Definition of applicable standards
  • Risk assessment
  • Criteria for quality control

Our approach

PROSE applied a hybrid reverse-engineering method that combined mobile 3D scanning, mesh processing, and feature-based CAD modelling to reconstruct the gear housing. In parallel, we coordinated with the third-party supplier Zoerkler to perform precision gear measurement, material analysis, and hardness verification.
All interfaces, tolerances, and functional surfaces were systematically cross-checked against the physical components and validated through a structured CSM-RA risk assessment.
Based on these inputs, PROSE established updated 3D/2D documentation and a technical specification defining material, heat treatment, tolerances and surface-finish requirements in accordance with railway safety and documentation standards.

Customer benefit

The long-term availability of spare parts is ensured through updated and complete technical documentation that enables reliable future manufacturing of spare parts. This significantly reduces the risk of obsolescence for the parts involved.
Thanks to PROSE’s hybrid reverse-engineering approach, combining mobile 3D scanning, mesh processing, and feature-based Computer-Aided Design (CAD) modelling, the technical documentation was delivered in a time-efficient manner. At the same time, we ensured an uncompromised level of safety and quality compared with the current gearbox parts.
Throughout the project, PROSE maintained continuous dialogue with all involved actors to achieve solutions that meet the customer’s needs, supported by our independent position and broad engineering expertise.

 

Railway axle handling equipment with a workshop fixture and CAD model of the axle lift and support console

Design and delivery of an axle lift and support console

Customer: Göteborgs Spårvägar, Sweden

Project tasks

  • Requirement capture
  • Engineering design
  • Manufacturing and logistics
  • Delivery within time, budget and quality
  • Training
  • Verification

Our approach

Our engineering team worked closely with the customer to define the functional and safety requirements for the axle lift and support console. Based on these inputs, we created the original design delivered three years ago, providing a stable and safe solution for axle handling.  For the repeat order, we coordinated the detailed design updates and worked with one of our trusted manufacturing partners to produce the second unit. This follow-up delivery allowed us to refine the proven concept with targeted improvements informed by the customer’s operational experience.

Throughout the project, we ensured clear communication, organised the necessary verification steps, and provided training to support safe and consistent use in the workshop.

Customer benefit

​The customer receives a fixture that supports safer and more controlled axle handling in the workshop. The design reduces the risk of axle movement and helps protect personnel and equipment during maintenance activities.
By working with PROSE, the customer benefits from a partner capable of managing the full chain from requirement capture to design, manufacturing coordination, verification, and training. Our independent engineering approach and familiarity with workshop processes ensure that the delivered solution is practical, reliable, and straightforward to integrate.
The decision to procure a second unit confirms that the original solution met the customer’s expectations and that the updated version continues to support their operational needs.

 

 

Integration and Authorisation Management: Polish Train Radio, Radio Stop Module, Interior and Exterior Foliation

Customer: ODIG – Ostdeutsche Instandhaltungsgesellschaft mbH, Germany

Project tasks

  • Integration engineering of the Polish train radio
  • Integration engineering of the radio stop module
  • Adaptation of the MESA23 system
  • Consideration of the interior and exterior foliation as well as the modification of the train radio system within the verification process
  • Homologation management
  • Authority communication

Our approach

ODEG – Ostdeutsche Eisenbahn GmbH operates passenger transport services in northern and eastern Germany. The fleet consists of Desiro Classic (BR 642) multiple units, among others, manufactured by Siemens Mobility (SMO). The maintenance and repair of the vehicles is carried out by ODIG – Ostdeutsche Instandhaltungsgesellschaft mbH. This is a 100% subsidiary of ODEG. The vehicles currently operate with the existing German authorisation and a German train radio system on a section of line that runs over Polish territory. In future, the vehicles will have to be equipped with Polish train radio system and a radio stop module (RSM). The RSM is a device that is connected to the existing train radio system and integrated into the vehicle’s safety loop via an electromagnetic valve. In this way, the responsible dispatcher can give the “radio stop” command, which opens the vehicle’s safety loop and brings the vehicle to a standstill. In addition, interior foliation in the WC and full-surface exterior foliation had to be installed.

The functionality of the existing MESA23 system will be expanded to include operation with Polish train radio and the radio stop module (RSM). The foliations are handled with regard to all requirements.

Customer benefit

Thanks to the cooperation with PROSE, the customer was able to successfully convert the Desiro Classic railcars (BR 642) to use Polish train radio and the radio stop module (FSM). This not only offers ODEG passengers increased safety during the journey, but also enables smooth operation on the section of line through Polish territory. The application of the interior and exterior foils also contributes to the attractive appearance of the vehicles.

PROSE managed the project from the initial idea to the authorization strategy, preparation of evidence documents and coordination with NoBo/DeBo/AsBo through to communication with the authorities, so that ODIG was able to obtain a significant part of the project scope from a single source.

 

    

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.

 

 

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.

 

  

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.

 

      

Design and authorisation strategy for a rail-bound maintenance machine

Customer: SCHÖMA, Germany

Project tasks

  • Vehicle authorisation strategy
  • Design assurance (Systems Engineering)
  • Concept development
  • Technical evaluation of offers and technical coordination with suppliers
  • Project management

Our approach

SCHÖMA plans to develop a proven, powered, three-part rail-bound maintenance machine with cab, loading platform and crane called HERO. SCHÖMA needs support in developing the authorisation strategy to fulfil the EN 14033 standards and in defining the design process including verification and validation.

PROSE developed the decision-making basis for the authorisation process enabling a defined combination of the three vehicles of the working machine to be approved and the verifications and evidence according to EN 14033 to be provided. PROSE also supported SCHÖMA in the budget planning phase of the development of the HERO work machine in the evaluation of supplier offers for systems and components such as the power train, braking system, power generation, train protection (ETCS) and heating, ventilation and air conditioning (HVAC). In addition, PROSE defined the design phases and the design assurance process according to the systems engineering methodology to ensure a defined and structured design process.

Customer benefit

PROSE has structured and optimised SCHÖMA’s development process by systematically applying the system engineering methodology. This approach has not only minimised development risks associated with costs and timelines but has crucially enhanced the predictability and likelihood of obtaining the necessary authorisation.

 

          

3rd party assessment of exterior camera installation

Customer: MTR Tech, Sweden

Project tasks

  • Assessment of proposed and installed solutions of camera installation
  • Highlighting risks and deviations from industry standards and recommendations

Our Approach

MTR has operated and maintained the X60 Coradia fleet on behalf of the Stockholm Region until 2024. The region has ordered installation of cameras from Alstom to support the drivers and improve visibility around the door-area, particularly on platforms with curved tracks.

PROSE has extensive experience in mechanical and electrical design as well as design processes, especially in adhesive bonding. Based on our expertise, an iterative assessment process has taken place to assess the proposed and installed solution. It includes recommendations in line with industry best practice for both mechanical design and bonding – as well as design and processes – in accordance with EN17460.

Customer benefit

​Adding additional equipment to an existing fleet without impacting the basic design requires experience and know-how about production methods and the original design. With PROSE as an independent assessor, the client received an independent assessment of the proposed and installed solution as well as the identification of potential short- and long-term risks in the proposed design of both the bonded joints and the mechanical parts.

 

      

Corrosion repair

Project tasks

  • Creating a CAD model of the carbody from a set of drawings
  • Creation of an FE model of the carbody
  • Strength assessment of the condition without corrosion
  • Consideration of corrosion damage in the calculation model
  • Analysis and determination of minimum wall thicknesses
  • Specification of measures for corrosion repair
  • Preparation of drawings to document the repair solution

Our Approach

Corrosion damage to the lower structure of the carbody was discovered during the planning of conversion measures on dining carriages. The wagons are welded steel constructions from 1990 and due to the advanced age of the vehicles, the operator did not have any CAD models or strength documents. PROSE was commissioned to assess the utilisation of the carbody in terms of strength. First in their original, corrosion-free state and then considering the identified corrosion damage. Additionally, we were asked to develop solutions to prolong the service life of the vehicles.

In a first step, a CAD model was created from the set of drawings. This model then served as the basis for creating the Finite Element (FE) model, which embodies the target condition of the carbody structure. A subsequent strength analysis then showed how many theoretical reserves the structure still had.

In the next step, the FE model was updated to include corroded areas, and the calculations were repeated. In this way, the effect of corrosion on the structural strength of the carbody could be determined and evaluated.

Using an iterative approach, a maximum corrosion depth could be determined for the damaged areas. For areas where it was foreseeable that the corrosion would penetrate too deeply, repair solutions were also developed, which included welding in new profiles, and their strength was verified.

Customer benefit

Thanks to PROSE’s work, the customer now has access to a CAD model of the carbody. The strength analysis has enabled the determination of minimum wall thicknesses for vehicle areas typically affected by corrosion, which the customer can use to evaluate the extent of corrosion damage. For areas where corrosion has penetrated too deeply, the customer now possesses localised repair solutions. This can significantly extend the service life of the vehicles.

 

          

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