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Digitalisation of maintenance requirements

Customer: SBB Historic, Switzerland

Project tasks

  • Research: Review and analysis of the existing documentation (e.g., old regulations)
  • Expert Interviews: Enrichment of the database with know-how from specialists
  • Documentation: Creation of maintenance plans for the 14 rail vehicles and 3-4 wagon fleets
  • Approval: Incorporation of client feedback and final adjustments

Framework conditions:

  • Utilisation of old regulations as the basis
  • Supplementation through reverse engineering and other methods to address data gaps
  • Collaboration with the client, particularly in providing knowledge and feedback

Our approach

The project was initiated by SBB Historic to gradually align the existing maintenance organisation and fleet management with European standards. The core challenge lies in transforming a fragmented documentation base. Many of the historic vehicles have only partially available operational and maintenance manuals, as the original manufacturers either no longer exist or the documentation has been lost over time.

Additionally, the introduction of the ZEDAS maintenance software is intended to support and future-proof the maintenance processes. The project aims to create a consistent and standard-compliant maintenance plan landscape for the historic rail vehicles, enabling efficient, safe, and resource-conscious maintenance. At the same time, the transition will ensure compliance with European norms and facilitate maintenance activities carried out by in-house teams, associations, and third parties.

To achieve these objectives, PROSE adopts a structured approach comprising several interconnected work steps. The process begins with extensive research, focusing on reviewing and analysing old maintenance regulations to compile and prepare existing content. Subsequently, PROSE conducts expert interviews to incorporate historical knowledge from specialists, fill existing gaps, or update outdated guidelines. Based on this, maintenance plans are developed for the 14 rail vehicles and three to four wagon fleets. These plans are created iteratively, incorporating client feedback to ensure a tailored solution. Finally, the plans are integrated into the new maintenance concept and adapted to the requirements of the ZEDAS software.

The PROSE team, consisting of experienced experts, guarantees a professional and quality-orientated implementation. If necessary, the team is supported by other experts to ensure the quality and efficiency of the implementation.

Customer benefit

The project provides the client with numerous advantages that go beyond merely developing maintenance plans. By establishing a consistent, standards-compliant planning framework, the maintenance of historic vehicles can be carried out safely, efficiently, and cost-effectively. The integration of existing regulations and the supplementation of missing content through expert interviews not only reduces time and financial expenditure but also ensures that the plans are highly practical and relevant.

Another significant benefit lies in the introduction of the ZEDAS maintenance software, a key component for future digitalisation and optimisation of processes. The combination of technical and operational expertise provided by PROSE ensures that the plans are seamlessly integrated into the new software ecosystem, creating a high level of efficiency and transparency.

With transparent pricing and an agreed cost ceiling, the project remains financially predictable and manageable. At the same time, SBB Historic and the participating organisations benefit from PROSE’s extensive experience and proven competence. PROSE delivers tailored and sustainable solutions in the railway sector. The outcome is not only technically flawless but also an economically viable solution that guarantees the long-term safe operation of the historic fleet.

 

 

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.

 

          

Expert opinion on carbody structures

Project tasks

Verification of

  • Design Concept and Philosophy
  • Carbody calculation specification
  • Carbody crash specification
  • Validation plan
  • Finite element descriptive document
  • Calculation results
  • Weldings

Our Approach

PROSE supported the established European rail vehicle manufacturer with reviews to ensure that the development of its carbody structures complies with all requirements (safety, durability, strength/rigidity) specified in the standards and is supplemented by customer requirements.

Two essential characteristics of carbody structure are crashworthiness and fatigue strength. To check these properties, design principles and calculation methods must be evaluated.

The evaluation focused on the customer’s stress report, which PROSE carefully checked. In addition to evidence of carbody straining by standardised loads, evidence of results from load scenarios in the end customer’s country is required. Such load scenarios are not directly defined in a standard but must be analysed. As this task is more complex, PROSE scrutinised this part of the report with particular attention.

Customer benefit

PROSE helped ensure the development of a cutting-edge aluminium carbody structure. The customer and the end customer highly valued its independent expert opinion as quality assurance.

With PROSE as an independent assessor, the customers had a further means of reducing design risks by using the expertise of PROSE’s seasoned engineers.

 

  

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.

PROSE Documentation services – Technical documentation

Project tasks

  • Technical writing
  • Information analysis
  • Document management
  • Review process work
  • Coordination of projects
  • Administration and management
  • Translation: Terminology management (English, German, Swedish)
  • Document management system PRO(doc)

Our Approach

PROSE assists in the creation and translation of new technical documentation, as well as revising and updating existing documents. Our technical writers help you create technical documents such as technical descriptions, maintenance manuals and spare parts lists. We review, both on the supplier and customer side, the language, structure, and contents of the technical documents, and perform quality control in line with established documentation requirements.

The technical writers produce technical documentation, working both in office and together with technicians and system engineers on site, to understand complex functioning of products and systems, thus creating clear documentation. The quality is assured through detailed checklists, verification on site and validation with the customer.

PROSE’s technical translators work with the support of professional translation software. The creation of custom dictionaries allows us to help you manage your company-specific terminology. At PROSE, we offer translation to, and from, Swedish, English and German.

We also offer our own document management system, PRO(doc). PRO(doc) is a customised online documentation management system. Developed by PROSE, it enables you to easily manage your documentation, such as technical drawings, maintenance instructions, trouble-shooting remedial actions, spare parts information and so on.

Customer benefit

PROSE has contributed to many projects by creating new technical documents, as well as by translation, review and coordination. The documents are written for train drivers, maintenance staff and training instructors, are verified on site and validated with the customer.

PROSE works both on the supplier side and on the customer side, contributing to a large amount of important documentation. Work in the depot environment ensures that complex functions are understood, to create clear documentation. This helps operators to understand the updated products and systems, ensures correct use of the products and enables and guarantees safety in maintenance work.

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.

    

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.

 

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.

 

Wheelset torsional vibration

Customer: Various customers

Project tasks

  • Basic assessment of the vehicle’s wheelset torsional dynamics
  • Analytical estimation for dimensioning the wheelset shaft and, if necessary, other components
  • Multibody simulations for a more detailed analysis for optimization
  • Consulting and support for homologation measurements and support for documentation for homologation.

Our Approach

PROSE accompanies the entire, or single sections of the process chain, from the pre-design of the wheelset shaft over the optimization of the mechanical components up to the execution
of the homologation measurements for the determination of the maximum, dynamic torsional moment. By means of analytical and conceptual investigations, a fundamental assessment of the wheelset torsional dynamics of the vehicle is already carried out in advance, taking into account the dimensioning of the wheelset, the powertrain configuration and drive systems. Based on the preliminary investigations, in-depth analyses are carried out in consultation with the customer using multibody simulation models. On the one hand, these investigations limit
the maximum dynamic torsional moment to be expected, indicate the component loads to be expected and, at the same time, describe other dynamic properties of the driveline. Considering the existing driveline configuration, its design properties are optimized in such a way that the mechanical damping of the first torsional eigenmode of the wheelset is increased, thereby reducing the maximum dynamic torsional moment. The results of the analyses provide relevant information for the system analysis required for certification, which describes the wheelset torsional dynamics of the vehicle. In addition, the analyses are used to determine the vehicle configurations critical for planning and performing the homologation measurements. Finally, the maximum dynamic torsional moment is determined with metrological tests on the vehicle.

Customer benefit

The analyses carried out help the customer to minimize risks in the approval of the wheelsets. The preliminary investigations enable realistic time and cost planning up to the approval of
the wheelsets. The in-depth analyses and component optimizations reduce the stresses caused by torsional vibrations and prevent damage to safety-relevant components during operation. Finally, the identification of critical operating conditions significantly reduces and secures the scope of the homologation measurement.

 

Strength analysis (FEA simulation)

Customer: various customers

Project tasks

Development of verification concepts and load assumptions as well as performance of calculations and simulations for:

  • Car bodies according to e.g. EN 12663
  • Bogies and wheelsets according to e.g. EN 13749, EN 13261
  • Streetcars and metros according to VDV 152
  • Attachment parts according to EN 61373
  • General load assumptions from calculations, measurements and simulations for e.g. special vehicles

Static, fatigue and time strength assessment:

  • Base material and weld seams according to FKM Guideline
  • Fatigue of steel according to Eurocode 3 DIN EN 1993-1-9 and BS 7608
  • Weld seam evaluation according to DVS 1612 / DVS 1608 and IIW recommendation
  • Screw connection according to DIN 25202:1-6, VDI 2230 and Eurocode 3 DIN EN 1993-1-8
  • Cylindrical helical spring according to EN 13906

Further analyses:

  • Nonlinear and crash analyses
  • Heat transfer analyses
  • Topological optimizations
  • Eigenvalue analyses
  • Stability analyses
  • Damage analyses and repair solutions

Our Approach

Depending on the customer’s specifications, PROSE carries out strength analyses in parallel with the design in its own development team or works directly with the customer’s team. PROSE covers the entire range of the analysis from the development of the load assumptions to the modelling to the efficient execution of the calculations and simulations as well as the evaluation of the results. Based on the strength analyses, PROSE can prepare test specifications for structural tests, accompany tests and, if required, validate the strength model with the evaluation. PROSE engineers have interdisciplinary know-how also in non-railway specific problems. Furthermore, PROSE also takes over the coaching of simulation processes and supports as a neutral consultant.

Customer benefit

Through the early use of strength analyses in the design process, weak points are identified and eliminated at an early stage, costly test series are avoided and the quality of the product is decisively improved. In addition to a qualified calculation, PROSE attaches great importance to the interpretation and presentation of the results required for the customer, including explanations and, if necessary, documentation relevant for approval. Due to its great flexibility, PROSE can respond to customer requests at very short notice

        

Fire protection monitoring technology IC 2000

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.

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