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Tag: Modernisation

Modernisation – Our solutions

Authorisation Support – Repainting of ET425.5 EMUs

Customer: Transdev Hannover GmbH, Germany

Project tasks

  • Project management
  • Requirements capture
  • Authorisation support
  • Communication with NoBo and DeBo
  • Preparation of evidence and admission documents
  • Preparation of a change notification

Our Approach

Transdev Hannover GmbH changed the existing colour scheme of 13 EMUs of the type ET425.5 from the Deutsche Bahn “Verkehrsrot” to the Transdev branding in blue and white. PROSE supported with authorisation management concerning TSI LOC&PAS, TSI PRM and German NNTR as well as requirements capture and evidence documents. The main obstacle was to find a way to establish the evidence documents of the fire protection as no spare parts existed to conduct the necessary experiments.

Due to the great experience and good networking within the industry, it was possible to agree on a feasible way of proving fire protection with the assessment bodies as early as the tendering phase. In combination with the close support of the customer in every phase of the project, loops or lengthy discussions could be avoided.

Customer benefit

PROSE led Transdev Hannover through the authorisation process including communication with the assessment bodies and project management. This ultimately resulted in the timely submission of the documents and rapid final processing by the national safety authority (EBA) including the final “Go”.

 

 

QA of suppliers and production for driver’s desk refurbishment in C20 Metro

Project tasks

  • Quality assurance of sub-suppliers
  • Supervision of prototype phase
  • First class installation
  • Delivery inspections

Our Approach

PROSE have worked closely with the suppliers from an early phase in the development process to ensure a smooth transition from development through prototype to the production ramp-up phase and to ensure stable quality throughout the serial production.

Customer benefit

By improving the supplier delivery early in the project, the customer could benefit from minimizing quality issues just before the start of production. PROSE’s wide range of available services helped the customer in many stages of the project.

 

Digitalisation Maintenance Instructions

Customer: SBB Historic, Switzerland

Project tasks

  • Research: Review of the old maintenance regulations for each vehicle
  • Expert interviews: Ensuring the transfer of expertise to supplement/correct the old maintenance regulations
  • Documentation: Creation of maintenance plans for each vehicle
  • Release: Incorporation of customer feedback and internal release of the maintenance plan

Our Approach

PROSE supports the client in creating maintenance plans for the first 14 traction units and 3-4 coach fleets. These can only be partially derived from old regulations and thus completed and adapted accordingly and transferred to a digitalised maintenance concept. A significant proportion of the maintenance work is carried out voluntarily by associations. This particular situation must be taken into account in the concept development. PROSE also provides relevant support for introducing the ZEDAS maintenance software on the customer side.

Customer benefit

The client receives a digitalised, standardised and consistent maintenance plan landscape for the vehicles to ensure the safe, standard-compliant and efficient planning and implementation of maintenance measures using in-house, association and external services.

The logic and conceptual design of the maintenance plans, regardless of whether they relate to steam locomotives, electric locomotives or multiple units, will be aligned accordingly, thus creating content, processes and documentation specifications that are much easier to understand and can also be communicated to volunteer maintenance staff to ensure safe rail operations.

The implementation already considers European standards for safe maintenance and their functional allocation in the organisational development. This will ensure a gradual expansion of the client’s maintenance services towards a modern, digital maintenance organisation.

   

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.

Grand-Tour luxury train maintenance plan

Customer: Arlington Fleet France, France

Project tasks

  • Project management
  • Maintenance management
  • Homologation support

Our Approach

The “Le Grand Tour” project is creating a luxury cruise train in France, using refurbished coaches from Deutsche Bahn. Arlington Fleet France (AFF) is overseeing the project, using existing maintenance data from DB and new system designs.

In the first phase, PROSE formalised existing data from Deutsche Bahn, which is crucial for creating the maintenance plan. Now, in the second phase, we’re taking the lead in drafting the maintenance plan and the Maintenance Documentation File, ensuring compliance with homologation requirements for seamless introduction and operation on the French network.

Customer benefit

Based on PROSE’s extensive experience, the entire maintenance plan was created by integrating the existing and newly added systems. This allows the customer to have a solid maintenance file for the train approval and the vehicle authorisation and, subsequently, to plan future maintenance operations.

    

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.

 

 

Optimisation of the heavy overhaul program for the Tram “Cobra”

Customer: Verkehrsbetriebe Zürich, Switzerland

Project tasks

  • Development of an evaluation matrix based on the VBZ vehicle structure
  • Determining which measures are to be implemented within the framework of R3
  • Development of a project manual applicable to the project

Our Approach

PROSE develops an evaluation matrix based on the VBZ vehicle structure so that it can be determined which measures should be implemented within the framework of R3. The evaluation matrix contains criteria according to which the measures can be evaluated, including an evaluation. PROSE is developing a project manual applicable to the CR3 project. The focus is on the definition of the different phases including their objectives, duration and contents. It also explains which project participants and stakeholders should be involved, when and how, and how responsibilities should be defined.

Customer benefit

The methodology and tooling provided by PROSE in the first phase enables VBZ to efficiently plan and implement Revision 3 and the life extension measures. The evaluation matrix enables VBZ to make informed decisions about which measures should be implemented as part of R3. This helps to use resources effectively and to keep the trams in the best possible condition. The project manual is the basis for VBZ to implement the Cobra tram overhaul and service life extension project in a structured and effective way, resulting in cost savings and efficiency gains.

     

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.

 

   

Assistance to the project owner for the renewal of contracts for the regional interurban public transport network

Customer: Région SUD , France

Project tasks

  • Project management
  • Provision of techno-commercial advice

Our Approach

Background: In the context of the evolution of the future scope of scheduled services, and considering the adoption of the Law of 24 December 2019, “Orientations des Mobilités”, the Transport Organizing Authority (AOT), the Southern Region defines its service offering.
The Region needed to strengthen these capacities in the face of the procedures for renewing contracts for the regional interurban public transport network in the Alpes de Haute-Provence region and the reorganisation of the Regional Express Lines in the areas concerned.

Approach: PROSE joined forces as a consortium to respond to this call for tenders. The consortium, led by the company Trans-missions, is made up of PROSE for its expertise in rolling stock, but also Tractebel for the infrastructure part.

Customer benefit

PROSE is supporting the South Region in the preparation, development and negotiation of a new operating agreement with SNCF Voyageurs. Our profound expertise in rolling stock empowers us to provide valuable advice for enhancing the terms of the operational monitoring contract. We focus on critical aspects such as reliability clauses, availability assurances, and proactive obsolescence monitoring. In the field of maintenance, PROSE’s expertise is made available for an accurate assessment of the advertised costs.

In the pursuit of the opening of regional passenger rail lines to competition, PROSE provides technical assistance on the new calls for tenders to come., Our technical expertise is poised to address critical areas, including:

  • ERTMS installation
  • Rolling stock maintenance
  • Sustainable development
  • Technical sizing of maintenance and siding sites, etc.

 

   

Re-design studies of the PRIMA BB27000 and BB37000 locomotives

Customer: AKIEM, France

Project tasks

  • Pre-studies (feasibility study and budget estimate on different topics)
  • Electrical and mechanical integration studies
  • Replacement of the headlights with LED headlights
  • Integration of a socket with USB ports in the driver’s cab.
  • Modification of existing circuit diagrams
  • Design of integration plans and schemes
  • Creation of an operating and an assembly manual
  • Budget estimate to modify the entire PRIMA fleet of AKIEM
  • Supply of prototype parts and support for its integration
  • Carrying out the procedure and the test report
  • Updating of documents after the integration of the prototype and the realisation of tests, if necessary
  • Provision of the purchase specifications of the parts for the series
  • Impact assessment of the amendment

Our Approach

To carry out all pre-studies and studies, PROSE has set up an internal organisation:

  • Project Manager / Coordinator
  • Electrical Engineers
  • Mechanical Design Engineer
  • Expert in change impact analysis

PROSE worked in collaboration with AKIEM to provide the best possible solution in the shortest possible lead time.

Customer benefit

Thanks to our expertise in the field of rolling stock and our engineering department with its various competence centres, PROSE was able to offer our best services to propose modifications and carry out innovations on the locomotives.

 

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