Tag: Mechanical vehicle & systems engineering

Mechanical vehicle & systems engineering – Our solutions

Fire protection monitoring technology IC 2000

2023-07-07

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

2023-07-07

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.

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

2023-07-06

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

2023-07-06

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.

Computational evidence of derailment safety for rack railway wagons

2023-07-06

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.

Engineering project IC2020-fleet

2023-04-10

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.

Mid-life maintenance of PRIMA BB27000 and BB37000 locomotives

2023-04-10

Customer: AKIEM, France

Project tasks

Definition of the operations to be carried out for the mid-life maintenance of PRIMA locomotives
Identification of ways to increase reliability
Treatment of component obsolescence
List of changes that can be implemented in mid-life operation
Solutions for a hardware refresh
Definition of the industrialization process for mid-life
Analysis of the risks associated with the residual life of the equipment

Our Approach

PROSE has developed a high level of expertise in the PRIMA-E locomotive type, maintenance definition and reliability growth action plan.

Customer benefit

Thanks to its expertise in the field of rolling stock, over the entire life cycle, PROSE can offer its best services to accompany its customer through all the stages of the life of its locomotives.

Modernisation of 135 Interregio coaches for operator Flixtrain

2023-04-10

Customer: Talbot Services GmbH, Germany

Project tasks

Creation of mechanical conversion
Preparation of circuit diagrams
Adaptation of air conditioning concept
Integration of new toilets
Integration of luggage racks
Certification support
Certification calculations
Mass management
Fire protection
Strength analysis

Our Approach

The Arkimbz, WRmbz, ABimdz, Bimdz and Bimz wagons were modernized, in following phases: starting-, initial-, planning, production- and execution phase. Finally the type test phase concluded the work.

Customer benefit

As a strategic engineering partner, PROSE was already able to convince the customer Flixtrain in the offer phase. When it came to the engineering work, you could rely on the skills of PROSE and thus focus on the conversion of the vehicles.

Refurbishment of X2000 class high speed trains

2023-04-10

Customer: Stadler, Sweden

Project tasks

Overall project management
Electrical and mechanical engineering of the interior
RAMS
Approval management
Technical documentation

Our approach

During the tendering phase PROSE acts as consultant for Stadler. In the project, PROSE is responsible for technical project management, electrical and mechanical engineering, approval and RAMS. PROSE will also provide technical documentation services.

Customer benefit

Our customer benefits from PROSE’s great expertise in X2000 trains, as part of our team was already involved in the last modernisation 10 years ago. In addition, thanks to the modernisation, passengers will enjoy a completely new travel experience on board Sweden’s fastest trains – with new interiors, new seats and more efficient lighting. The availability of the trains will also be improved. The result is a train set that passengers will experience as completely new.

Implementation of the approval project for lifting platforms used on tunnel maintenance vehicles

2023-04-10

Customer: SBB Infrastructure, Switzerland

Project tasks

Homologation management
Risk analysis on system level
Verification of stability by calculation
Verification of occupational safety, railroad safety

Our Approach

In a first phase, the basics for approval had to be elaborated for the two applications. Then, the feasibility was evaluated concluding a proof of stability, but also regarding commercial aspects. The necessary measures were derived here after to ensure safe operation. This report was discussed with the customer and the responsible authority (FOT). In the second phase, the customer implemented the measures, PROSE controlled this implementation and prepared an evidence report.

Customer benefit

With the practical knowledge of the involved persons from SBB and PROSE, simple, cost-effective and practicable measures could be realized. The step by step process lead to legal certainty without investment before it was clear, that the project will reach its objective. By considering worker’s safety from the very beginning, the approval process could be simplified. Thus, no separate approval with a second approval authority was necessary, reducing time and costs as well as the related approval risk.

Development of suspended monorail vehicles

2023-04-10

Customer: Kiepe Electric GmbH, Germany

Project tasks

Mechanical design of carbody, vehicle interior and running gear
Mechanical system integration
Manufacturing supervision
Homologation management

Our Approach

In order to overcome the first challenge of creating the optimized vehicle for this particular application, PROSE developed a vehicle body that is constructed from aluminium extrusion profiles.
Moreover, the continuous low floor and wide-opening doors guarantee efficient passenger flow. The new vehicles for the Wuppertal suspension railway also offer high driver comfort.

Customer benefit

Given PROSE’s extensive experience in developing mainstream and special projects of all kinds, PROSE’s development team was able to successfully meet Kiepe Electric GmbH’s expectations. Furthermore, PROSE’s intercultural experience and capabilities are highly appreciated, playing a fundamental catalyst role in the current manufacture of the vehicles in Austria, Germany and
Spain.

Design of a 100% low-floor tram

2023-04-10

Customer: CRRC Sifang Co Ltd, China

Project tasks

Tram concept
Design and development of bogie and carbody conceptual design and development
Electrical concept
Mechanical system integration

Our Approach

In cooperation with the client, PROSE developed the system specification for the whole tram and several of its components. One of the most challenging tasks in 100% low floor-trams is the design of the bogie, which had to be both compact and offer a quality ride. Single wheels were the solution.

Customer benefit

The newly designed 100% low-floor tram is a major upgrade of CRRC Sifang’s tram portfolio. The integration of CRRC Sifang’s production know-how and related processes into PROSE’s design work means lower production costs for CRRC Sifang.