Skip to main content

Tag: Validation – Verification

Validation – Verification – Our solutions

SBB FLIRT EVO – Factory Acceptance Tests (FAT): Test specification interior & exterior indicators

Customer: Stadler Bussnang AG, Switzerland

Project tasks

  • Define software interface test matrix
  • Check interface documents
  • Carrying out laboratory and vehicle tests
  • Logging of the test execution
  • Final discussion and definition of the next steps

Our approach

Stadler has been commissioned by the Swiss Federal Railways (SBB) to supply the new FLIRT fleet. An important part of the project is the integration of various passenger information system components, including LED and TFT displays, into the APFZ 2.0 system developed by SBB. During the course of the project, however, problems arose with the interface integration of Stadler’s supplier for the display technology, which were only discovered relatively late. These challenges led to functional faults in the vehicles.

As Stadler had limited resources at its disposal, PROSE was commissioned to gain an overview of the situation within a very short space of time. PROSE was tasked with checking the specifics and developing a comprehensive test script and test matrix with the help of information from Stadler and SBB. The aim was to quickly identify the exact causes of the problems that had arisen by carrying out tests in the laboratory and directly on the vehicles.

Customer benefit

By working with PROSE, the customer benefits from extensive expertise in software development as well as interface and protocol management. With PROSE’s support, the problems encountered could be analysed in a structured manner and their causes investigated by means of carefully planned tests. Stadler, SBB and the supplier of the displays all benefited from this expertise and came much closer to solving the technical difficulties.

 

    

Expert report on metre-gauge flat wagons with cogwheel brake

Customer: PVF Trade, s.r.o., Czech Republic

Project tasks

  • Project management
  • Definition and procurement of input data
  • Review and appraisal of all input documents
  • Preparation of expert report

Our Approach

PROSE was commissioned by the company PVF Trade, s.r.o., to prepare an expert test report (SV report) on the test report of suspension tests of the vehicle “four-axle service – flat wagon 1000mm track with cogwheel brake”.

The report is intended to provide information on the compliance of the brake tests according to the test report “Flat wagon with toothed wheel brake suspension tests” with the provisions of the AB-EBV and their fulfilment.

All documents submitted were checked for completeness and plausibility. The check was carried out against all relevant requirements from the FOT guidelines AB-EBV.

In the event of inconsistencies and/or missing information, these were requested from the client or other project partners. On this basis, a final expert report was prepared and submitted to the client.

Customer benefit

​PROSE’s prompt preparation of the expert report guarantees a smooth and rapid handling of the authorisation procedure. The intensive review of the documents provided ensures that the report meets the highest quality standards and that the vehicle is guaranteed to operate safely. The intensive project supervision by the PROSE expert regarding adjustments and requirements for the documentation with all project partners relieves the customer of this organisational work and ensures rapid and high-quality processing.

 

 

Delivery of four dummy bogies

Project tasks

  • Project management
  • Manufacture

Our Approach

PROSE was commissioned to develop and manufacture four customised dummy bogies for the depot. The main challenge was to design robust bogies suitable for use in the demanding conditions of a workshop environment. These bogies not only need to have a high load capacity but also have to offer flexible adaptability to different vehicle types and maintenance requirements of the depot. The manufacturing process required carefully selecting materials and technologies that ensure long-term durability and resistance to mechanical stresses and environmental influences. In addition, special attention was paid to ergonomics and user-friendliness to ensure the safety of depot employees and increase the efficiency of maintenance processes. The technical specifications were worked out in detail in close cooperation with the customer to ensure that the finished bogies are optimally adapted to the depot’s specific requirements and existing infrastructure.

PROSE tackled this task with a focused approach to quality and functionality. The four dummy-bogies were manufactured under strict quality control and using high-quality materials. Each bogie was carefully designed to meet the specific requirements of the depot, with particular attention paid to durability and ease of maintenance. The noise reduction target of >1dB set at the beginning of the project was successfully achieved with a theoretical analysis.

Customer benefit

​The provision of these four customised dummy-bogies offers the customer considerable advantages. Thanks to the improved reliability and robustness of the bogies, maintenance work can be carried out more efficiently and safely. This leads to a significant reduction in downtime and an increase in operational safety in the depot. The customised bogies, therefore, not only support daily routines but also help to improve the service life and performance of the vehicles maintained in the depot.

 

   

Gearbox investigation on vehicles

Project tasks

  • Project management
  • Create a feasibility study
  • Test proposals based on the preliminary study
  • Evaluation from tests
  • Recommendations

Our Approach

The feasibility study involved testing the sealing proposals recommended by PROSE on two different gearboxes of the vehicle. One gearbox was found to have a minor leakage, while the second gearbox showed similar levels of leakage as before, despite the use of a sealing compound and a regular O-seal. These tests helped to evaluate the effectiveness of the various proposed sealing methods and provided valuable data for the further development of the solutions.

Customer benefit

​Based on the results of the tests, PROSE can now make specific recommendations for further steps. PROSE, therefore, recommends that the next step is to test the X-seal and simultaneously apply two lines of sealant to the motor output shaft. This recommendation is based on the observed performance of the tested seal variants and aims to develop a more robust solution to prevent oil leakage. This strategic approach allows the customer to make targeted adjustments and improvements to resolve the problem in the long term and improve the operational reliability and service life of the gearbox.

 

    

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.

 

  

Inspection and assessment of carbody, cracks and corrosion

Project tasks

  • Project management
  • Planning of the project
  • Inspections
  • Establishing an assessment report

Our Approach

As part of the project implementation, PROSE AB carried out thorough inspections on all 9 X60A vehicles to ensure their structural integrity. This was carried out with visual inspections of the vehicle frames and bodies to identify visible damage. This meticulous approach made it possible to precisely document every potential weak point, which allowed targeted planning for necessary repair work. Through the comprehensive inspection and documentation, PROSE AB ensured that all vehicles’ safety and quality requirements were met, improving their operational safety and longevity.

Customer benefit

​By providing nine detailed inspection reports, one for each vehicle, the customer benefited from a comprehensive and accurate overview of the condition of their vehicle fleet. The individual reports provide an accurate assessment of each vehicle’s condition and maintenance needs. This structured and detailed documentation enables the customer to make informed decisions about necessary maintenance and repair measures, helps to optimise operational safety and supports effective resource planning. The reporting thus increases transparency and facilitates strategic planning for the long-term maintenance of the vehicle fleet.

 

     

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.

Vehicle procurement – Manufacturing Supervision, Quality Control and Factory Tests

Customer: various customer

Project tasks

  • Acceptance of the welded car bodies / bogie frames
  • Paint inspection and acceptance
  • Intermediate acceptance of main electrical components
  • Intermediate acceptance of interior fittings
  • Factory acceptance/customer acceptance

Our Approach

By regular participation in the vehicle acceptance tests and constant coordination with the team of the vehicle manufacturer, PROSE checks the quality of the production. The customer is permanently kept up to date by the acceptance team regarding the progress of the production as well as possible complications or deadline postponements. He immediately receives the results of the production controls and acceptances and can follow up changes, modifications etc.

The dates for the acceptance of components, intermediate assembly stands and vehicles ready for delivery follow the production plan but are also handled operationally and flexibly in order to be able to react to specific occasions. In this way, control of the construction process is always ensured and there is the possibility of intervention in the event of difficulties such as quality slumps, scheduling, supply, or capacity problems.

Customer benefit

With manufacturing supervision, the manufacturer’s quality assurance process is checked and monitored in addition to the product quality, because every vehicle has gone through this process before it is presented for factory acceptance. Continuous construction supervision ensures consistent quality at a high level.

      

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.

 

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

        

Brake and thermal calculation locomotive Aaem841

Customer: Müller Technologie AG, Switzerland

Project tasks

  • Define and obtain input data
  • Brake calculation in TrainBrac
  • Thermal calculation in ANSYS
  • Specification and selection matrix for brake blocks

Our Approach

PROSE defines and procures the input data based on the relevant standards, which are required for the approval of the vehicle. Subsequently, the calculations were carried out and optimized so that the defined requirements were met. For this purpose, a brake calculation in TrainBrac was created in close coordination with the customer, as well as a thermal brake calculation in ANSYS, in order to prove the performance of the brake.  PROSE also contacted various brake block suppliers for possible linings on the basis of the specifications and calculation results and prepared a selection and decision matrix for Müller Technologie AG, including recommendations for the selection of a suitable lining.

Customer benefit

Thanks to PROSE’s expertise in this field, the customer receives documents to prove the performance of the modernised brake, which comply with the relevant standards and can thus be submitted 1:1 to the assessor/expert to achieve approval. Furthermore, the specification and pre-evaluation of the brake blocks material with decision support enables an efficient enquiry of possible suppliers.

Mid-life maintenance of PRIMA BB27000 and BB37000 locomotives

Customer: AKIEM, France

Project tasks

  • Definition of the operations to be carried out for the mid-life maintenance of PRIMA locomotives
  • Identification of ways to increase reliability
  • Treatment of component obsolescence
  • List of changes that can be implemented in mid-life operation
  • Solutions for a hardware refresh
  • Definition of the industrialization process for mid-life
  • Analysis of the risks associated with the residual life of the equipment

Our Approach

PROSE has developed a high level of expertise in the PRIMA-E locomotive type, maintenance definition and reliability growth action plan.

Customer benefit

Thanks to its expertise in the field of rolling stock, over the entire life cycle, PROSE can offer its best services to accompany its customer through all the stages of the life of its locomotives.

info@prose.one

 

Our solutions

 

© PROSE. All rights reserved
Disclaimer    Privacy Policy