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Tag: Validation & Verification

Validation – Verification – Our solutions

Vande Bharat train at platform – sleeping car unit representing bogie design validation project in India.

Design validation of bogies for Vande Bharat sleeping cars

Customer: Ramkrishna Forgings Limited, India

Project tasks

  • Bogie design validation
  • Creation of 3D models for all bogie types
  • FEA of the bogie frame types and high-loaded components
  • Preparation of bogie frame fatigue test specification
  • Welding inspection onsite
  • Update of existing drawings to improve manufacturing quality

Our approach

PROSE was commissioned by RAMKRISHNA FORGINGS LIMITED (RKFL) to perform independent design validation of the bogie assemblies for the new sleeping car coaches of the Vande Bharat train. The work focused on verifying the structural and functional compliance of the existing passenger car bogie for the sleeping car configuration. We performed Finite Element Analysis (FEA) and assessed conformity with relevant railway standards, providing the technical justification required to support the design modifications and approval for operation.

PROSE provided RAMKRISHNA FORGINGS LIMITED (RKFL) with independent technical validation of the bogie design for the sleeping car configuration of the Vande Bharat train. Drawing on our expertise in structural, safety and system analysis, and our deep understanding of international railway standards, we ensured a reliable and efficient assessment of the existing design

Customer benefit

As an independent engineering partner, PROSE supported RKFL from analysis through testing and documentation, helping to secure the operational readiness and approval of the new sleeping cars for service on the Indian rail network. Furthermore, RKFL receives manufacturing documents tailored to RKFL’s production capabilities.

 

    

Assessing locomotive compatibility on an SJ Rc6 electric locomotive in Sweden, showing roof-mounted pantographs and high-voltage equipment at a station platform.

Assessing locomotive compatibility under increased overhead line voltage

Customer: SJ AB, Sweden
End customer: Trafikverket, Sweden

Project tasks

  • Technical investigation
  • Documentation research
  • Identification of possible changes in locomotive high-voltage circuits
  • Cost estimation of the changes
  • Integration of the changes in the actual system

Our approach

PROSE began with a structured review of the Rc6 high-voltage system, analysing design documentation, component specifications, and historical modification records to establish the vehicle’s current technical baseline. Based on this analysis, we evaluated the impact of the increased maximum voltage on insulation coordination, component voltage margins, and protection systems. Where necessary, we developed alternative technical solutions to ensure compliance with the new operating conditions. Each option was assessed from both a technical and economic perspective, including feasibility, implementation effort, operational implications, and associated risks. The work was carried out in close dialogue with SJ as operator and Trafikverket as infrastructure owner to ensure transparency and alignment throughout the project.

Customer benefit

The customer gained a transparent and technically sound decision basis for operating the Rc6 fleet under increased overhead line voltage. Our independent assessment clarified voltage margins, component limitations, and protection requirements, creating full visibility of technical risks and modification needs.
By systematically comparing refurbishment scenarios, including cost and implementation implications, we enabled SJ and Trafikverket to prioritise measures based on safety, operational reliability, and long-term investment protection. With PROSE’s in-depth knowledge of Swedish rolling stock and infrastructure interfaces, the operators secured a technically robust and future-proof solution aligned with updated network standards.

 

Open door of a C20 metro driver cab in Sweden, illustrating onboard modifications and the need for verified electrical documentation.

Documenting a reconstructed electrical design for a metro driver cab air conditioning system

Customer: MTR Tech AB, Sweden

Project tasks

  • Collection of as-built electrical information from customer
  • Technical review and consolidation of handwritten updates
  • Reconstruction of electrical schematics
  • Verification of correctness and consistency
  • Formal release of approved drawings

Our approach

The project addressed the absence of controlled and verified electrical documentation following the installation of a new air-conditioning unit in the driver cab of a C20 metro vehicle operating in Sweden. The modification had been implemented by the customer, with electrical schematics updated manually, resulting in missing traceability, inconsistent information, and non-compliance with railway documentation standards. The objective was to reconstruct the as-built installation, verify the electrical design, and formally document and release correct, complete and compliant electrical drawings.

PROSE collected and reviewed all available technical input from the customer, including as-built installation details and handwritten updates to existing schematics. Based on this information, we analysed, consolidated, and reconstructed the electrical design and documented it into formal electrical schematics in accordance with applicable railway documentation standards. The resulting drawings were verified and issued under PROSE authorship, in close coordination with the customer’s engineers, ensuring accuracy, traceability, and controlled release. PROSE’s independence and deep understanding of railway electrical systems enabled efficient reconstruction even with incomplete and informal source material.

Customer benefit

By selecting PROSE, the customer obtained verified and formally released electrical documentation that accurately reflects the as-built installation. This restored full traceability, ensured compliance with railway documentation standards, and created a reliable basis for safe operation, maintenance, and future modifications. PROSE’s independent engineering approach and experience in reconstructing and validating modified or legacy designs reduced project risk and relieved pressure on the customer’s internal engineering resources.

 

   

Assembly of a red funicular carriage with new air suspension chassis during the modernisation of an alpine funicular railway, accompanied by PROSE.

Chassis development funicular railway

Customer: Steurer Seilbahnen AG, Switzerland

Project tasks

  • Project management
  • Weight management
  • Feasibility study
  • Concept development
  • Verification concept and load assumptions
  • Strength calculation
  • Manufacturing support

Our approach

As part of the modernisation of the funicular railway from Unterwasser to Iltios in the Toggenburg region, Steurer Seilbahnen AG selected PROSE as its partner for the development of a custom running gear with air suspension – specially designed for funicular railway applications.

Steurer Seilbahnen AG has designed an innovative concept for a funicular railway chassis with air suspension and one-sided longitudinal force transmission. Building on this foundation, PROSE worked with Steurer to develop detailed requirements specification and carried out a concept validation. The constructive realisation was carried out at Steurer with technical support and coordination from PROSE. Our team handled the full structural design and strength verification, including equalisation safety. We also defined the measuring point plan for the test runs and delivered a comprehensive comparison report to support strength validation. To ensure an optimal solution, close cooperation between all parties involved was key during the iterations between design and strength.

Customer benefit

The combination of Steurer’s and PROSE’s expertise in funicular railways and air suspension resulted in a constructive and efficient co-operation that always kept an eye on all aspects, right through to verification. PROSE’s flexibility and proactive project management – together with Steurer’s practical insight – enabled design optimisations to be seamlessly integrated during procurement and manufacturing. This close cooperation ensured a technically sound, thoroughly verified solution tailored to the specific needs of funicular railways.

 

        

Blue and white Västtrafik tram on route 3 to Kålltorp travelling through a historic city street in Gothenburg, Sweden.

Reverse engineering of new gears and housing for trams

Customer: Västtrafik AB, Sweden

Project tasks

  • Measuring of the gearbox housing
  • 3D modelling and technical drawings
  • Material definition
  • Definition of applicable standards
  • Risk assessment
  • Criteria for quality control

Our approach

PROSE applied a hybrid reverse-engineering method that combined mobile 3D scanning, mesh processing, and feature-based CAD modelling to reconstruct the gear housing. In parallel, we coordinated with the third-party supplier Zoerkler to perform precision gear measurement, material analysis, and hardness verification.
All interfaces, tolerances, and functional surfaces were systematically cross-checked against the physical components and validated through a structured CSM-RA risk assessment.
Based on these inputs, PROSE established updated 3D/2D documentation and a technical specification defining material, heat treatment, tolerances and surface-finish requirements in accordance with railway safety and documentation standards.

Customer benefit

The long-term availability of spare parts is ensured through updated and complete technical documentation that enables reliable future manufacturing of spare parts. This significantly reduces the risk of obsolescence for the parts involved.
Thanks to PROSE’s hybrid reverse-engineering approach, combining mobile 3D scanning, mesh processing, and feature-based Computer-Aided Design (CAD) modelling, the technical documentation was delivered in a time-efficient manner. At the same time, we ensured an uncompromised level of safety and quality compared with the current gearbox parts.
Throughout the project, PROSE maintained continuous dialogue with all involved actors to achieve solutions that meet the customer’s needs, supported by our independent position and broad engineering expertise.

 

Blue and red trains at a snowy outdoor station platform at night, illustrating rail coupler upgrade and electrical interface integration for snowblower wagon type B257

Coupler upgrade and electrical interface integration

Customer: MTR Tech AB, Sweden

Project tasks

  • Requirements capture and definition of electrical interface
  • Design review
  • Update of technical documentation
  • Verification of electrical connections and signal integrity
  • Official drawing release and configuration control
  • Coordination with MTR during implementation and validation

Our approach

PROSE contributed to the design definition of the new electrical interface and collaborated closely with MTR engineers during system implementation of the upgraded coupling system be-tween the Snowblower Wagon Type B257 and the C20 train.
While MTR carried out on-site installation and testing, we re-viewed, clarified, and consolidated the draft electrical updates and ensured that all connections and signal interfaces complied with safety and operational requirements.
The verified and approved information was issued as official electrical drawings, released under PROSE authorship and re-viewed by MTR engineers.
This cooperative approach ensured full traceability, correctness, and compliance with railway documentation standards.

Customer benefit

​The customer gained a reliable and standardised coupling solution that reduced manual work in demanding winter conditions. The upgraded interface improved operational efficiency by ensuring full mechanical and electrical com-patibility between the snowblower wagon and the C20 fleet. Independent engineering review by PROSE ensured high quality and compliant documentation, providing confi-dence in the safety and integrity of the system. The result is a future-ready solution that supports safe, efficient, and well-documented winter operations.

 

 

Technical support and documentation for the modernisation of the EMU class 72

Customer: Alstom, Sweden

Project tasks

  • Requirements capture
  • Electrical system engineering
  • Technical writing

Our approach

PROSE provided technical support and documentation for the modernisation of the EMU vehicle class 72. An electrical systems engineer ensured that key upgrades—such as LED front lighting, USB ports, and interior lighting—met modern standards. In addition, two technical writers were assigned to update the existing technical documentation to reflect the improvements.

Our electrical systems engineering team took a methodical approach to ensure that all subsystems met functional requirements and complied with current standards and regulations. Our focus was to check subsystems such as LED front lights, USB contacts and passenger information systems (PIS). When we found gaps between existing components and required standards, we recommended improvements. Our thorough approach ensured that every aspect of the electrical system was optimised for modern operational efficiency and regulatory compliance.

Customer benefit

Our expertise allowed for a quick project start, helping the customer save valuable delivery time. ALSTOM also appreciated PROSE’s support on safety and regulatory matters, ensuring all requirements were met efficiently.

 

      

Validation Maintenace activities- Mälartåg

Customer: AB Transitio, Sweden

Project tasks

  • Validation of the maintenance process

Our approach

Transitio, as the owner, and MTR, as the operator of the Mälartåg trains, are responsible for validating the maintenance processes. This validation serves to complete the maintenance instructions and identify efficiency improvements in the maintenance processes. The train manufacturer Stadler is obliged to fulfil the contractually agreed specifications to ensure that maintenance is carried out to the highest standards.

The validation of the maintenance process is divided into five main phases:

  • Requirements planning and definition: This is where requirements are determined and clearly defined.
  • Definition of specifications and configurations: In this phase, the exact specifications and configurations are determined.
  • Verification: This phase serves to carefully review the previously defined specifications and configurations.
  • Utilisation: After the definition of requirements, design and qualification, which includes testing and commissioning, the utilisation phase follows. During this phase, continuous checks are made to ensure that the validated status is maintained. This is usually the longest phase and aims to ensure that the defined standards are continuously met throughout the entire service life.
  • Decommissioning: The final phase involves the orderly decommissioning of the system while maintaining the documented standards until the end.

The aim of this structured procedure is to maximise efficiency and safety.

Customer benefit

Monitoring the initial qualification of devices and compliance with defined processes during the utilisation phase are essential. This enables effective process verification, which allows potential deviations to be recognised at an early stage. In this way, preventive measures can be taken before deviations occur. This preventive monitoring and early correction make a significant contribution to maintaining the quality and reliability of operational processes.

 

     

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.

 

  

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