Skip to main content

Tag: Mechanical vehicle & systems engineering

Mechanical vehicle & systems engineering – Our solutions

Development of suspended monorail vehicles

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

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.

 

Bogie engineering in Finland

Customer: Transtech Oy, Finland

Project tasks

  • Design and development of the bogie
  • Running gear design
  • Structural analysis
  • Simulation and analysis of running behaviour
  • Infrastructure test of structural stability and durability, and of load distribution
  • Detailed design for manufacturing

Our Approach

In this project, PROSE provided a full range of engineering services, including running-gear design for the whole vehicle, calculation of structural strength and durability, and detailed design. Simulation and analysis of running behaviour and measurements on Helsinki tram lines yielded important information on structural stability and durability and on load distribution.

Customer benefit

The result of the eight-month development period for the customer is a compact and robust powered bogie that is specifically suited to both Helsinki’s weather and the tram’s low-floor concept. In this process, the customer was able to concentrate fully on their core expertise, manufacturing, while PROSE took charge of developing all necessary documentation. As a corporately independent service provider, PROSE offered the customer system-oriented skills for the full life cycle of a rail vehicle.

Turnkey engineering for a freight wagon with sliding wall for high-speed operation

Customer: CRRC Jinan, China

Project tasks

  • Conception and development of the bogies, the car body structure and the sliding wall mechanism
  • Calculations of the running dynamics and the aerodynamics
  • Structural strength analyses
  • Preparation of component specifications, production drawings, assembly instructions and manuals
  • RAMS / LCC

Our Approach

PROSE performed the entire development process at several locations. PROSE can perform all services, e.g. engineering, design, analyses and calculations, project management etc., at several locations, which cooperate closely, but, of course, the internal communications between the various locations is also always ensured.
The manufacture and the approval tests were performed by the customer, but PROSE provided active support.

Customer benefit

Thanks to PROSE’s extensive experience with the various vehicle components at its various locations, PROSE can offer comprehensive turnkey engineering services. Our customer profits from PROSE’s know how due to the close cooperation and the mutual visits.

 

Adaption of German maglev train technology for operation in China

Customer: Shanghai Maglev Transportation Development Co. Ltd (SMTDC), China

Project tasks

  • Modification of the German maglev train TR08 in line with the requirements of a commercial operation in Shanghai
  • Support of reassembly of vehicles in Shanghai, commissioning and the start of operation
  • Realization of a maintenance optimization program with quality control processes
  • Performance of employees training in vehicle mechanics and on-site vehicle assembly

Our approach

PROSE engineers, at that time as members of ThyssenKrupp Transrapid, supported the successful reassembly, commissioning and start of operation of the German maglev train TR08 for Shanghai Maglev Transportation Development Co. Ltd. Thereafter the vehicles were modified in line with the requirements of a commercial operation in Shanghai. A suitable, adjusted maintenance optimization program with quality control processes was developed and established. Training for maintenance personnel was carried out. Until 2019 PROSE audited the world’s fastest train operation and its maintenance on a yearly basis.

Customer benefit

Successful operation of the maglev train in China was ensured because of PROSE’s yearly on-site inspections since 2011.

 

Development of a gauge-changing facility for operator MOB

Customer: Chemin de fer Montreux Oberland bernois MOB, Switzerland

Project tasks

  • Feasibility analysis
  • Mechanical and control engineering development
  • Detailed Manufacturing Design
  • Strength analysis
  • Support Approval

Our Approach

In cooperation with MOB, PROSE has developed the gauge-changing facility in several phases from a simple prototype to a complex series production system.

Customer benefit

From an early stage of the development of the gauge change system, PROSE supported MOB in approval issues. The complexity of the numerous interfaces between the gauge-changing facility and the vehicles, the infrastructure as well as the train protection systems of MOB and BLS were taken into account by PROSE through a close cooperation with the involved partners. From the conceptual design to the successful commissioning, MOB could be supported solutionoriented and target-oriented from one source.

Support for the approval of an automatic coupler

Customer: SBB Cargo, Switzerland

Project tasks

  • Analysis and description of the modifications
  • Formulation of the proposed modifications
  • Classification of the modifications and associated risks in accordance with RTE 49100
  • Preparation of an approval concept
  • Preparation of the documents to be presented to the FOT
  • Integration of FOT’s comments into the approval concept

Our Approach

PROSE managed the homologation process and supported the coordination between SBB Cargo and the Federal Office of Transport (FOT) to achieve the approval for the automatic coupler for commercial operation.

Customer benefit

The customer gains an overview of the valid regulations to be considered for the approval process with the FOT. Consequently, the authorities received a fast processing time and later the customer a lean, efficient verification and issue of the operating approval. PROSE has made a valuable, risk-minimising contribution to the “automatic couplers” project which is essential for the success of the strategic automation programme.

Multi-body simulation for providing evidence for safety against derailment for a metre gauge vehicle

Customer: PVF Trade, s.r.o., Czech Republic

End customer: Montreux-Berner Oberland-Bahn (MOB), Switzerland

Project tasks

  • Composition of the modelling parameters
  • Creation of the MBS model for each wagon type
  • Implementation of the boundary conditions in the simulation environment
  • Carrying out and evaluating the simulations
  • Evaluation of the results
  • Documentation in a verification report

Our Approach

The computational verification of safety against derailment in twisted track curves was carried out in accordance with the BAV guideline based on EN14363:2016 using method 1 with test conditions adapted for metre gauge.

Customer benefit

Due to the broad experience of the experts at PROSE with the MBS modelling and simulation of rail vehicles and the performance of computational verifications, the derailment safety verification for the metre gauge vehicles could be carried out efficiently and in target-oriented manner.

Verification of clearance between infrastructure gauge and infrastructure

Customer: Stadtwerke München GmbH (SWM), Germany

Project tasks

  • Support of the SWM project management in the technical evaluation of the results of the infrastructure survey
  • Interpretation of the results with regard to the requirements resulting from §18 of the BOStrab (German regulation on the construction and operation of tramways)
  • Recommendation of the measures to be taken
  • Preparation of the final report of the initial survey for the individual metro lines for submission to the technical supervisory authority

Our Approach

​With laser surveying, the existing installations are recorded with a precision that was previously impossible. PROSE supports the SWM project management in the technical evaluation of the results of the infrastructure survey. This includes the interpretation about the requirements resulting from §18 of the BOStrab as well as the measures to be taken. In addition, PROSE prepares the final report of the initial survey for the individual metro lines for submission to the technical supervisory authority.

Customer benefit

PROSE has experts with many years of expertise regarding the interaction of infrastructure and vehicle and especially regarding the clearance of the light area. This enables PROSE to advise clients on the interpretation of the applicable guidelines in case of ambiguous facts. PROSE was able to prove to SWM that several objects, which were initially classified as violating the clearance, do not pose a threat regarding the clearance. Thus, the customer could avoid a cost-intensive dismantling of these objects.

Support for the purchase of low-floor trams

Customer: Basel public transport authority (BVB), Switzerland

Project tasks

  • Capture customer wishes concerning vehicle technology
  • Support documentation of the resulting technical requirements
  • Consider the current state of technology
  • Take account of current technical rules and standards
  • Revise the draft specification
  • Conduct a technical evaluation of the submitted bids

Our Approach

PROSE employs experts with many years’ experience in rail passenger transport. This allowed PROSE to put the tender call in a correct and due form and to state the customer’s requirements so as to facilitate their practical implementation. PROSE also brought in current technical rules and standards and took current laws and regulations into account.

Customer benefit

The customer gained value because the PROSE experts, reduced the commitment of customer resources in the tender call’s development and because PROSE introduced knowledge of current technology and of corresponding systems and components in developing the concept for the tram. PROSE took into account the experience of other public transport agencies in recent rolling stock procurement projects and contributed to a neutral and impartial bid evaluation.

 

Development of a standardised EMU requirements specification for EN15380-5 transverse elements

Customer: Swiss Railway undertaking, Switzerland

Project tasks

  • Summarise the current situation and clarify needs in one document
  • Concept development incl. review
  • Implementation in specification reviews (statement and walk-through / inspection)
  • Training and presentation of results

Our Approach

For the respective cross-sectional topics according to EN 15380-5, PROSE created one-pagers for the mutual understanding of the topics, which were reviewed together with the client’s technical experts.

Customer benefit

By creating the standard specifications, which define and describe the requirements regarding the cross-section elements, the customer has final procurement documents at train level. 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 cross-section elements.

Car body (bodyshell) development

Customer: Vossloh Kiepe GmbH, Düsseldorf, Germany

End customer: Public transport company of Wuppertal, Germany

Project tasks

  • Development of the mechanical vehicle modules, i.e. car body and bogie
  • Project management
  • Definition and supervision of component tests
  • Homologation support

Our Approach

PROSE was responsible for the complete engineering of the main mechanical modules of the vehicle, which were the car body and the bogie.

Customer benefit

Given that PROSE was in charge of the vehicle development, customer VKD, who previously had been a component supplier, was able to expand its portfolio to the delivery of complete vehicles to the end customer. The know how of PROSE’s engineers in the field of turnkey engineering of complete vehicles, which is based on many years of experience with light-weight construction, was a basic condition for the successful results.

info@prose.one

 

Our solutions
© PROSE. All rights reserved
Disclaimer    Privacy Policy