Tag: Modernisation

Modernisation – Our solutions

Expert assessment – Operation of UIC and AAR brake systems in the same train

2023-04-06

Customer: Israel Railways Ltd., Israel

Project tasks

Analysis and comparison of the standards for UIC and AAR brake systems
Analysis and comparison of technical differences and operational characteristics of the two brake systems
Analysis of brake systems of the existing vehicles
Identification of technical and operational risks for the various train compositions

Our Approach

ISR commissioned PROSE with the preparation of an independent expert assessment to find out whether it is possible and safe to operate a train with different brake systems. The study focused on the analysis and comparison of the standards for UIC and AAR brake systems as well as on the technical differences and operational characteristics of the two brake systems. The brake systems of the existing vehicles were analysed, and the technical and operational risks for the various train compositions identified.

Customer benefit

ISR has now an independent expert assessment about the risks of operating trains that consist of AAR locomotives and UIC freight wagons. Moreover, PROSE listed the measures together with a suggested solution for the immediate reduction of the operational risks and for the long-term stable operation of trains which consist of both AAR and UIC rolling stock.

Gauging analysis

2023-04-05

Project tasks

Gauging analysis of railway vehicles according to EN 15273
Gauging analysis of vehicles according to BOStrab
Calculation with special simulation programs cMotion or DIMA
Simulation of complex articulated vehicles, e.g. light rail vehicles
Consideration of national requirements (e.g. EBO resp. BOStrab in Germany or AB-EBV in Switzerland, etc.)
Consideration of requirements from network accesses (e.g. SBB I-20030 in Switzerland)
Gauging analysis of narrow-gauge vehicles according to AB-EBV
Analysis of special vehicles (e.g. suspended railways)

Our Approach

At first a verification concept is developed based on the customer’s specifications as well as requirements from infrastructure and standards. This can include the following, depending on the specific task:

Simple delta analysis (e.g. design adaptions or interoperability concerns)
Regular construction gauge calculation with static or kinematic methods
Calculation of gauging demand by means of accumulation of critical positions of the bogies in the track gauge, design tolerances, plays, etc. with distinction of random and non-random contributions
Simulations by means of the tool cMotion to model arbitrary vehicle configurations and track routing
Application of dynamic methods supported by simulations (e.g. swinging characteristics for suspended railways)
Development assisting analysis with continuous assessment and consulting
Validation via simulation or measurement (e.g. multi-body simulation or field test runs with attached blocks)
Compilation of input data, procedure and results to a report, ready to be submitted to Technical Authorities

Customer benefit

Due to the wide range of available methods and the long-standing expertise of the PROSE-experts arbitrary vehicles and requirements can be investigated. Potential problems will be anticipated and prevented. Manifested problems can be furthermore solved by experts of other disciplines. Additionally, a special focus on efficiency lies in our DNA as a service provider. Combined with a tailor-made concept for the customer and project this overall ensures that technical risks in development, homologation and operation as well as commercial overall efforts will be minimized.

Ad interim locomotive fleet manager

2023-04-05

Customer: SBB Cargo, Switzerland

Project tasks

ECM Migration
ANSF Approval Re484
Re484 Analysis power converter, compressor, emergency stop
Planning R2 Re484
Planning R2 Re474
Midlife measures Re482
Technical Mentoring Obsolescence Manager: Competence Matrix ECM2
Leadership Coaching ECM2 Manager: White paper and concept for Life Extension Re620

Our Approach

In addition to ensuring operational safety within the framework of the ECM2 function compared to the upstream and downstream ECM functions, PROSE took care of the sustainable improvement of the availability of the new fleet. The integration of PROSE experts in technical questions considerably increased the expertise available on site.

Customer benefit

With this ad interim solution, the customer SBB Cargo received a flexibly deployable expertise with broad technical support from PROSE, who quickly and filled this specific personnel assignment. In addition to the operational security function within the framework of ECM2, this solution provided increased benefits in terms of availability, development and regulations. In addition, PROSE led the newly appointed obsolescence manager in the establishment of the competence matrix of the ECM2 team for the auditcapable mapping of competence management within the framework of technical mentoring.

Leadership Coaching ECM2 Manager for life cycle extension locomotive Re620

2023-04-05

Customer: SBB Cargo, Switzerland

Project tasks

Review of contents Re620
Technical Mentoring old Locomotives Fleet Manager
Leadership Coaching ECM2-Manager in Conceptualisation

Our approach

PROSE developed a three-stage concept as part of a professional coaching phase for the current ECM2 manager of SBB Cargo; taking into account the stabilisation of reliability and availability up to 2035 at the level of 2020 and the completion of revision R2 with a defined content, a planned annual mileage up to End of Life (EoL) of 120 thousand kilometres p.a. or 1.8 million km and a removal of the separation between light (SBB Cargo) and heavy maintenance (SBB-P, Bellinzona industrial plant), which had arisen as a result of the organisational split-up within the SBB Group.

Customer benefit

This concept gave SBB Cargo a sustainable opportunity to operate the strategically important Re6/6 fleet for a further fifteen years. The current ECM2 manager received management coaching at the appropriate level for the conception of a fifteen-year life extension for the Re620 (SLM) old locomotive from the 1970s.

Strength verification of bonded joints IC Bt

2023-04-02

Customer: SBB, Switzerland

Project tasks

3D FE modelling
Derivation of loads
Definition of load cases
Evaluation of load cases
Verification report
Adhesive drawings

Our Approach

For the following connections, bonding proofs were developed on the basis of FEM calculations:

Car body structure – front cabin
Front cabin – front window
Front cabin – side window
Front cabin – rear view mirror
Front cabin – headlights
Front cabin – handle

PROSE prepared the strength verifications and adhesive drawings of the A1 bonding’s according to DIN 6701. In advance, the loads were determined according to EN 14067-5 and the load cases were defined according to EN 12663. Afterwards, the relevant load cases were evaluated and documented in the report.

Customer benefit

PROSE’s experience and certification in accordance with “DIN 6701, bonding of rail vehicles”, helps the customer to able to complete the verification dossier and thus obtain flawless re-registration of the vehicle.

SAMMS-t710: Structural strength analysis

2023-04-02

Customer: L&S Luddeneit und Scherf GmbH, Germany

Project tasks

Structural strength analysis of SAMMS-t710 freight vehicle.
Creation of mid-surface Finite Element Model (FEM)
Definition of load case and boundaries conditions
Interpretation of simulation result according to EN12663-2010
Creation of structural strength report

Our Approach

L&S contracted PROSE to demonstrate the strength of the SAMMS-t710 modification they designed as per EN 12663-1 by means of a finite element analysis (FEA). PROSE did assess the design modification in light of EN 15085-3:2010, then create a 3D model for calculation, define the loads cases together with L&S, perform the simulation, assess the results with presentation in a report. We also did support with design adaptation where required to reach EN 12663 fulfilment.

Customer benefit

By contracting PROSE, L&S did benefit from our wide experience in structural strength analysis. This led to faster and efficient design integrity calculation and adaptation of design when required to ensure structural integrity of the rail grinding vehicle car body main structure.