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Tag: Obsolesence

Obsolesence – our solutions

Finding potential suppliers for X10 bearing

Customer: Stadler Service Sweden AB, Sweden

Project tasks

  • Documentation review
  • Risk assessment
  • Specification update
  • Procurement management

Our approach

On behalf of Stadler Service AB, PROSE conducted a detailed preliminary study to identify reliable suppliers for an obsolete slewing ring bearing for the X10 trains. Given the challenges posed by the obsolescence of the existing components, this project aims to ensure sustainable sourcing solutions and support the long-term maintenance and availability of the train units.

In the first step, PROSE reviewed the customer’s existing relevant documentation and updated the requirement specifications according to the increased mechanical loads. In the second step, we identified and contacted several potential suppliers from within and outside Europe and discussed possible solutions in terms of both technical feasibility and cost efficiency.

Customer benefit

PROSE provided the client with a report containing a shortlist of potential suppliers and their respective offers. To assist the client in rapidly selecting a supplier, PROSE added its assessment of the suppliers and the corresponding offers as well as a subsequent recommendation.

 

  

Corrosion repair

Project tasks

  • Creating a CAD model of the carbody from a set of drawings
  • Creation of an FE model of the carbody
  • Strength assessment of the condition without corrosion
  • Consideration of corrosion damage in the calculation model
  • Analysis and determination of minimum wall thicknesses
  • Specification of measures for corrosion repair
  • Preparation of drawings to document the repair solution

Our Approach

Corrosion damage to the lower structure of the carbody was discovered during the planning of conversion measures on dining carriages. The wagons are welded steel constructions from 1990 and due to the advanced age of the vehicles, the operator did not have any CAD models or strength documents. PROSE was commissioned to assess the utilisation of the carbody in terms of strength. First in their original, corrosion-free state and then considering the identified corrosion damage. Additionally, we were asked to develop solutions to prolong the service life of the vehicles.

In a first step, a CAD model was created from the set of drawings. This model then served as the basis for creating the Finite Element (FE) model, which embodies the target condition of the carbody structure. A subsequent strength analysis then showed how many theoretical reserves the structure still had.

In the next step, the FE model was updated to include corroded areas, and the calculations were repeated. In this way, the effect of corrosion on the structural strength of the carbody could be determined and evaluated.

Using an iterative approach, a maximum corrosion depth could be determined for the damaged areas. For areas where it was foreseeable that the corrosion would penetrate too deeply, repair solutions were also developed, which included welding in new profiles, and their strength was verified.

Customer benefit

Thanks to PROSE’s work, the customer now has access to a CAD model of the carbody. The strength analysis has enabled the determination of minimum wall thicknesses for vehicle areas typically affected by corrosion, which the customer can use to evaluate the extent of corrosion damage. For areas where corrosion has penetrated too deeply, the customer now possesses localised repair solutions. This can significantly extend the service life of the vehicles.

 

          

Process for managing component reverse engineering

Customer: AB Transitio, Sweden

Project tasks

  • Develop a reverse engineering process
  • Ensure parts availability
  • Address business aspects

Our Approach

AB Transitio owns and leases out various EMU and DMU fleets in many regions of Sweden. For rolling stock owners, the lack of documentation and obsolescence, which can occur for different reasons, is a common challenge. Through this project, AB Transitio aims to establish a standardised process and methodology for managing specific cases of obsolescence using reverse engineering. The above-depicted process defines the general tasks, requirements, and responsibilities for handling reverse engineering cases, regardless of who operates and maintains a particular fleet.

PROSE has extensive experience in reverse engineering, safety management and vehicle acceptance procedures. Based on this expertise, we have developed a step-by-step process for the reverse engineering of parts, systems or components. This process ensures that all relevant standards and regulations are complied with. The result is a financially sound, maintainable and sustainable solution that ensures the vehicle can be maintained, repaired and overhauled throughout its life cycle.

Customer benefit

Reverse engineering plays a crucial role in fleet management and ensures sustainable, stable, and long-term maintenance of the fleet. By applying the methodology and process developed by PROSE, customers have access to parts and components that are available for maintenance, repair, or overhaul throughout the vehicle’s lifetime. This process also takes into account the commercial aspects of each case and ensures that the organisation carrying out the work has the necessary skills and expertise.

 

 

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