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.
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.
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.
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.
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
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.
Failure mode effects and criticality analysis (FMECA)
Our Approach
PROSE has created the fire protection analysis and the corresponding fire protection material list for VOGT. Furthermore, input data were collected for LCC and FMECA analyses. These data were inserted in the project-specific templates. As a result, documents were created according to the specifications of the end customer.
Customer benefit
PROSE has taken responsibility for VOGT to provide the correct input data for Fire Protection, LCC, and FMEC analyses and to create the documents by the end-customer accepted quality. This relieved VOGT of tasks that are outside their core business.
Preparation of the technical procurement documents BöB/VöB
Technical evaluation of suppliers
Preparation of the technical documentation for the retrofit
Accompanying prototype production on site in Olten
Updating commissioning instructions
Updating maintenance documents
Support in the approval process
Creation and monitoring of weight management
Our Approach
In a first step PROSE investigated the measures identified by SBB in the study phase and worked out the concept. PROSE prepared the technical procurement documents, such as specifications, technical requirement catalogues and interface drawings. The offers submitted by the potential suppliers were technically evaluated by PROSE and adjusted in the course of the technical negotiations. In the detailing phase, the system to be delivered was integrated into the vehicle documentation in cooperation with the suppliers who were awarded the contract by SBB.
Customer benefit
An international team of specialists from 4 countries is involved in the project at PROSE. Due to the project organisation PROSE is close to the customer SBB and therefore part of the overall project team. The creation of the production documents was done directly in the IT environment of SBB.
The Arkimbz, WRmbz, ABimdz, Bimdz and Bimz wagons were modernized, in following phases: starting-, initial-, planning, production- and execution phase. Finally the type test phase concluded the work.
Customer benefit
As a strategic engineering partner, PROSE was already able to convince the customer Flixtrain in the offer phase. When it came to the engineering work, you could rely on the skills of PROSE and thus focus on the conversion of the vehicles.
PROSE contributed to the project by assisting in creation of new technical documents for the refurbished train fleet, as well as with translation, coordination, and internal review. Around 400 documents have been created for the project, and subsequently reviewed by the customer. PROSE’s team of technical writers contributed to update, and create new system manuals, maintenance manuals, spare parts catalogues, troubleshooting guides, diagnostic data sheets (DDS lists), component sheet, training documentation, etc.
Customer benefit
PROSE supported ABB and Stadler in the creation and translation of new technical documentation for SJ. The documentation was created in the office, combined with work in the depot, to make sure every product/function was clearly described. This helps operators to understand the updated products and systems, ensures correct use of the products and guarantees safety in maintenance work.
Electrical and mechanical engineering of the interior
RAMS
Approval management
Technical documentation
Our approach
During the tendering phase PROSE acts as consultant for Stadler. In the project, PROSE is responsible for technical project management, electrical and mechanical engineering, approval and RAMS. PROSE will also provide technical documentation services.
Customer benefit
Our customer benefits from PROSE’s great expertise in X2000 trains, as part of our team was already involved in the last modernisation 10 years ago. In addition, thanks to the modernisation, passengers will enjoy a completely new travel experience on board Sweden’s fastest trains – with new interiors, new seats and more efficient lighting. The availability of the trains will also be improved. The result is a train set that passengers will experience as completely new.
Customer: ATI (Ansaldo Breda, OFV and Magliola), Italy
End customer: Trenitalia, Italy
Project tasks
RAMS analysis guidelines
Safety analysis guidelines
RAMS analysis for the systems from ATI
Verification and validation of the systems from the sub suppliers
Documentation services
Protocol and test procedures
Study and analysis for CEI UNI 11170 application
RAMS analysis at coach level
Our Approach
PROSE elaborated the guidelines and the templates to realize the RAMS analysis. Furthermore, PROSE carried out a coach risk analysis and generated hazards (SFAS) relating to each system in the driver’s cab and the coaches.
Customer benefit
Thanks to PROSE‘s extensive experience with RAMS analyses and documentation services, the costumer was able to focus on the design. PROSE was responsible for the project management with the support of Ansaldo Breda’s RAMS office. Therefore, the approval of the RAMS documentation by Trenitalia was simplified and unproblematic. Furthermore, the Vivalto coaches are the first coaches to which CEI UNI 11170 was applied, which means that PROSE, ATI and Trenitalia can benefit from this experience for other applications in future projects.
