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Tag: Mechanical vehicle & systems engineering

Mechanical vehicle & systems engineering – Our solutions

Fire Safety Assessment and Consulting

Project tasks

  • Consultancy
  • Development and creation of fire protection concepts
  • Development and creation of evacuation concepts
  • Analyses of fire protection requirements
  • Compilation of required fire protection test reports
  • Communication with authorities, manufacturers and testing laboratories
  • Integration of fire safety systems
  • Preparation of approval documents relevant to fire protection

Our Approach

PROSE analyses the given situation and develops solutions that meet the applicable fire protection requirements. To this end, PROSE advises the customer and identifies various solutions in order to find an efficient way of achieving the required fire protection for railway vehicles in accordance with EN 45545. Our experts calculate the thermal load of the vehicle during the design and propose measures for its reduction.

Customer benefit

The customer benefits from our many years of experience in the field of fire protection for all types of rail vehicles in accordance with EN 45545, including not only advice but also the creation of concepts, the preparation of the necessary fire protection certificates, contact with manufacturers of fire protection-compliant components and communication with approval authorities. The aim is to place fire protection suitable vehicles into service.

Vehicle procurement – Manufacturing Supervision, Quality Control and Factory Tests

Customer: various customer

Project tasks

  • Acceptance of the welded car bodies / bogie frames
  • Paint inspection and acceptance
  • Intermediate acceptance of main electrical components
  • Intermediate acceptance of interior fittings
  • Factory acceptance/customer acceptance

Our Approach

By regular participation in the vehicle acceptance tests and constant coordination with the team of the vehicle manufacturer, PROSE checks the quality of the production. The customer is permanently kept up to date by the acceptance team regarding the progress of the production as well as possible complications or deadline postponements. He immediately receives the results of the production controls and acceptances and can follow up changes, modifications etc.

The dates for the acceptance of components, intermediate assembly stands and vehicles ready for delivery follow the production plan but are also handled operationally and flexibly in order to be able to react to specific occasions. In this way, control of the construction process is always ensured and there is the possibility of intervention in the event of difficulties such as quality slumps, scheduling, supply, or capacity problems.

Customer benefit

With manufacturing supervision, the manufacturer’s quality assurance process is checked and monitored in addition to the product quality, because every vehicle has gone through this process before it is presented for factory acceptance. Continuous construction supervision ensures consistent quality at a high level.

      

Managing system and electrical engineering for a tramway

Project tasks

  • Project management
  • System engineering
  • Electrical engineering

Our Approach

Managing the systems engineering of tramways demands a methodological and detail-oriented approach. Bearing the technical responsibility for systems and electrical engineering in the new rail vehicles, our approach is characterised by precision, innovation, and meticulous attention to every intricate detail. We ensure that every aspect aligns with the highest industry standards.

Customer benefit

Our commitment to overseeing tramway systems engineering delivers tangible benefits to our customers. By assuming comprehensive technical responsibility for the systems and electrical engineering of the new rail vehicles, along with substantial involvement in their development, we guarantee a product of unmatched quality. For the vehicles, this translates into enhanced reliability, operational efficiency, and cutting-edge innovation, where our customers are granted risk mitigation, shorter time to market and overall satisfaction at every turn.

     

Aerodynamics simulation (CFD)

Customer: Various customers

Project tasks

​During the development process or during modernisation, aerodynamic influences such as crosswind or vehicle air conditioning of a vehicle must be assessed. Often the final verification requires investigations in a wind tunnel or climatic wind tunnel. However, CFD (Computational fluid dynamics) simulations are ideal for an initial assessment and optimisation, as they generally provide reliable results at significantly lower cost.

Analyses:

  • Crosswind stability (aero-dynamic coefficients and wind characteristics curves) according to EN 14067-6
  • Climatic studies and thermal comfort

Our Approach

Crosswind assessment according to EN 14067-6

The EN 14067-6 provides for the evaluation of crosswind with aerodynamic coefficients, which can be obtained either by wind tunnel tests or by CFD simulations. PROSE can determine these coefficients by CFD simulations and derive characteristic wind curves. The influence of the vehicle design on the crosswind stability can be considered in the design phase. In the case of changes to the vehicle exterior shape during conversions, the influence can be assessed and in the case of minor changes, proof of crosswind stability can also be provided.

Investigation of vehicle air conditioning

CFD simulations allow first estimations for climatic-technical investigations according to European standards, which are based on tests in the climatic wind tunnel. An optimisation with CFD simulations within the scope of the design of the air conditioning system generates additional safety and can avoid costly adjustments and repetitions of measurements in the climatic wind tunnel.

Customer benefit

PROSE can support you during the development process or during a modernisation with CFD simulations to reduce costs and risks of wind tunnel and climatic wind tunnel tests.

 

 

MBS simulation – trailer load with container car

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 cogwheel supporting wagon to be investigated as well as of the coupled train configuration
  • Execution and evaluation of the simulation
  • Documentation in a verification report

Our Approach

PROSE is to prove by simulation that derailment safety is given with the new requirements and to develop a set of arguments that can be submitted to the BAV to adapt the driving service regulation.

In a first step, PROSE compiled all the parameters required for modelling and simulation on the basis of customer data. Subsequently, the braking scenario was determined and agreed with the customer. PROSE created the multi-body simulation model (MBS model) of the container car in the required modelling depth. The overall model of the train set included a simplified MBS model of the necessary vehicles for the combinations to be verified in addition to the carrying car to be investigated. PROSE simulated the operationally most critical cases and recorded the results and evaluation of the simulations in a verification report for the attention of the approval authority.

Customer benefit

The customer received a verification report for the approval documentation, which clearly and comprehensibly documents the mathematical proof of safety against derailment of the cogwheel carrier car. On the basis of the proof, the customer was able to obtain the adjustment of the driving service regulation from the BAV.

   

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.

 

   

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.

 

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

        

Evaluation of offers for new KVG tram vehicles

Customer: Kasseler Verkehrs-Gesellschaft, Germany

Project tasks

  • Answering bidders’ technical questions
  • Support during the presentation of the workshop infrastructure to the bidders
  • Development of criteria for the evaluation-relevant requirements
  • Evaluation of the indicative offers regarding the fulfilment of the technical specifications
  • Preparing, assisting, and recording negotiations
  • Evaluation of binding offers regarding the fulfilment of the technical specification

Our Approach

PROSE assists the Kasseler Verkehrs-Gesellschaft (KVG) with technical expertise from the time of publication of the tender until the award of the contract. KVG was supported particularly in the priority areas of:

  • Answering bidders’ questions
  • Bid evaluation and
  • Support during bidder discussions

Based on the technical specifications, which were developed with the support of PROSE, the bidders’ questions were answered. PROSE established a small agile team for the bid evaluation, which started the intensive and systematic evaluation after receipt of the bids. The team was engaged in the same composition for the indicative as well as for the binding offers. In addition to adhering to the demanding schedule, this required close coordination with the KVG project team. At a joint workshop on-site in Kassel, the bidder discussions were prepared, and criteria for the evaluation-relevant requirements were developed.

Customer benefit

The customer can benefit from broad and independent expert support by PROSE:

  • Reduced binding of own resources for the development of the requirement specification.
  • Supplementing own technical knowledge with external knowledge for the general vehicle concept and the associated subsystems and components
  • Drawing on experience from PROSE’s broad pool of experts
  • Fast, structured and always comprehensible processing of the evaluation of almost 2000 requirements and 200 offer documents
  • Support in the preparation of the award decision

   

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.

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