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Tag: Validation – Verification

Validation – Verification – Our solutions

Modernisation of 135 Interregio coaches for operator Flixtrain

Customer: Talbot Services GmbH, Germany

Project tasks

  • Creation of mechanical conversion
  • Preparation of circuit diagrams
  • Adaptation of air conditioning concept
  • Integration of new toilets
  • Integration of luggage racks
  • Certification support
  • Certification calculations
  • Mass management
  • Fire protection
  • Strength analysis

Our Approach

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.

 

Audit of an ERTMS onboard system

Customer: Banedanmark (BDK), Denmark

Project tasks

  • Performance of the audit of the onboard projects of the Danish Signaling Program for the readiness for fitment
  • Assessment of the preparation for the installation phase of the vehicles in relation to:
    – Planning of the installation
    – Installation design
    – Prototype installation
    – Approval process
    – Assessment of different design issues

Our Approach

PROSE’s team of experts carried out this audit in less than three months; the audit covered the supplier Alstom, four railway operators, the national safety authority (Trafikstyrelsen), G-ISA and Banedanmark.

Customer benefit

Thanks to PROSE’s independent recommendations, our customer was able to optimize the current technical performance and to reduce the known risks.

Implementation of the approval project for lifting platforms used on tunnel maintenance vehicles

Customer: SBB Infrastructure, Switzerland

Project tasks

  • Homologation management
  • Risk analysis on system level
  • Verification of stability by calculation
  • Verification of occupational safety, railroad safety

Our Approach

In a first phase, the basics for approval had to be elaborated for the two applications. Then, the feasibility was evaluated concluding a proof of stability, but also regarding commercial aspects. The necessary measures were derived here after to ensure safe operation. This report was discussed with the customer and the responsible authority (FOT).  In the second phase, the customer implemented the measures, PROSE controlled this implementation and prepared an evidence report.

Customer benefit

With the practical knowledge of the involved persons from SBB and PROSE, simple, cost-effective and practicable measures could be realized. The step by step process lead to legal certainty without investment before it was clear, that the project will reach its objective. By considering worker’s safety from the very beginning, the approval process could be simplified. Thus, no separate approval with a second approval authority was necessary, reducing time and costs as well as the related approval risk.

Development of a gauge-changing facility for operator MOB

Customer: Chemin de fer Montreux Oberland bernois MOB, Switzerland

Project tasks

  • Feasibility analysis
  • Mechanical and control engineering development
  • Detailed Manufacturing Design
  • Strength analysis
  • Support Approval

Our Approach

In cooperation with MOB, PROSE has developed the gauge-changing facility in several phases from a simple prototype to a complex series production system.

Customer benefit

From an early stage of the development of the gauge change system, PROSE supported MOB in approval issues. The complexity of the numerous interfaces between the gauge-changing facility and the vehicles, the infrastructure as well as the train protection systems of MOB and BLS were taken into account by PROSE through a close cooperation with the involved partners. From the conceptual design to the successful commissioning, MOB could be supported solutionoriented and target-oriented from one source.

Expert assessment running dynamics of TramTrains

Customer: TÜV Rheinland, Germany

End customer: STADLER RAIL VALENCIA S.A.U., Spain

Project tasks

  • Creation and structuring of the verifications (in Karlsruhe for the EBO area, in Chemnitz for the EBO and BOStrab areas)
  • Monitoring of experiments
  • Expert assessment for the approval of the two tram trains according to §32 EBO in Germany (driving technology completely according to EN 14363) and in Chemnitz also according to BOStrab

Our Approach

In a first phase, the coordination of processes and the scope of approval with the competent authorities is therefore essential. This often also influences the duration of the approval process, the costs, and the risks. PROSE developed the verification concept together with the manufacturer. In a second phase, the agreed reports to provide evidence were prepared. This was done with the involvement of the manufacturer and the testing authorities. In the third phase these reports were assessed and finally the expert report was prepared

Customer benefit

The wide experience of the experts at PROSE lead to an optimal definition of processes and requirements from the beginning. This reduced process risks right from the beginning and ensured adequate stakeholder management. The active process design lead to a solid and target-oriented verification process involving authorities, manufacturers, test laboratories and other third parties. The customers also appreciated the swift feedback on the submitted documents and, in case of problems, the support in finding solutions.

Expert reports on running dynamics

Customer: Various customers

Project tasks

  • Driving evaluation of all types of railway vehicles including specialties such as two-way vehicles and tram trains
  • Driving evaluation and assessment of work and stability of crane vehicles, lifting platforms, excavators, bridge soffit devices, etc.
  • Accompaniment of speed increases of existing vehicles
  • Driving assessment on assignment of network access points
  • Extension of approval in State A based on approval in State B

Our Approach

In a first phase, the processes and the scope of approval is negotiated with the responsible authorities. This is essential as it dominates the time and costs of the approval process as well as the risks involved. In a second phase, the agreed evidence is then provided (simulations and tests performed) and evaluated. In the third phase, the expert report is prepared based on these reports on simulations and tests and – if required – represented before the authorities.

Customer benefit

The vast experience of PROSE’s experts leads to an optimal definition of processes and requirements from the beginning. Customers also appreciate the swift feedback on the submitted documents and, in case of problems, the support in finding solutions. Especially in countries without formal recognition of experts, it
is important that the customer can expect that the expert opinion will be accepted by the regulatory authority. The broad acceptance of PROSE’s experts ensures this.

Expert report on running dynamics of an Atlas road-railexcavator

Customer: Atlas GmbH, Germany

Project tasks

  • Structuring of approval requirements and proofs
  • One-time monitoring of tests for the first vehicle variant
  • Expert assessment for the approval of the road-rail-excavation according to §32 EBO in Germany (running dynamics incl. safety against derailment and stability criteria)

Our Approach

PROSE has developed the verification concept together with the manufacturer, witnessed some selected type tests and prepared the expert report based on the basis of the reports on calculations and tests provided.

Customer benefit

The wide experience of the experts at PROSE leads to an optimal definition of processes and requirements from the beginning. The active process design leads to a solid and target-oriented verification process involving authorities, manufacturers, test centers and other third parties. The customers also appreciate the quick feedback on the submitted documents and, in case of problems, the support in finding solutions.

 

Development and delivery of module test stands for railroad construction machines

Customer: Plasser & Theurer, Export von Bahnbaumaschinen, Gesellschaft m.b.H., Austria

Project tasks

  • Development, delivery and commissioning of test benches for vehicle modules for construction machinery (e.g. power pack, cabin)

Our Approach

For the specific implementation of the tests, PROSE developed suitable algorithms for an optimal test process. PROSE was responsible for the complete delivery of the test stand in the project, from the conception and construction to the delivery of the fully assembled test benches.

Customer benefit

Plasser&Theurer benefited from PROSE’s engineering experience during the project. By outsourcing the entire development and engineering project, the customer had the advantage of having fully designed and assembled test benches available by the time the first vehicle modules were completed. The commissioning of the test benches by PROSE ensured that the components to be pre-tested only had to be mounted and connected to the test frame, which significantly reduced the overall production and commissioning time.

 

Running dynamics analysis of rail vehicles (MBS simulation)

Customer: various customers

Project tasks

  • New vehicle developments:
    Feasibility clarification, risk hedging (failure conditions) and support of concept finding through computational evidence.
  • Vehicle approval:
    Simulation calculation for proof of fitness for running certificate, simulation and calculations for extension of approvals, simulation for determining vehicle prices in the train-path pricing system.
  • Problem solving in operation:
    Cause clarification after derailment, computational validation of potential changes, analysis of conspicuous wear phenomena, wheel rail interface study.
  • Special operational conditions:
    Pushing/pulling of inoperable multiple units, propelling tests
  • Wheel set torsional vibrations (rolling)
  • Special applications such as gauge change bogies, maglev or (suspended) monorails

Our Approach

PROSE covers the entire range of simulation, from the definition of the simulation task and boundary conditions of the system to the compilation of the required model parameters, model building, efficient execution of the simulations and evaluation of the results. Due to its many years of experience, PROSE is able to estimate parameters in a qualified manner that are difficult to determine and to select the appropriate modelling depth for the respective problem. The commercial software system SIMPACK as well as special applications developed in-house are available for the simulation calculations. Depending on the customer’s requirements, PROSE carries out analyses during the design process in the own development team or works directly with the customer’s team. PROSE also contributes interdisciplinary know-how in non-railway-specific problems.

Customer benefit

Qualified simulation calculations reduce the development risk or help to solve problems that have occurred. In addition to a qualified calculation, PROSE attaches great importance to the interpretation and presentation of the results required by the customer, including explanations and, if necessary, documentation relevant to homologation. Furthermore, PROSE also takes over the coaching of simulation processes and supports customers as a neutral consultant. Due to its great flexibility, PROSE can respond to customer requests at very short notice.

         

MBS-calculation safety against derailment of an electric track vehicle

Customer: ROBEL Bahnbaumaschinen, Germany

Project tasks

  • MBS-calculations to evaluate safety against derailment in track twists based on the EN14363:2019
  • Investigation with cranes in transfer mode and in two different working positions
  • Determining of existing reserves of the lifting load
  • Presentation of the results regarding the EN14033-2:2017 appendix H to the technical supervisory authority (TAB)

Our Approach

PROSE created an MBS model of the track vehicle and simulated runs through critical curves with superelevation and maximum track twist considering the specifications from the EN14363 for the vehicle in transfer mode and in two different working positions with corresponding crane position and lifting load.

Customer benefit

With the MBS-simulations PROSE was able to prove the safety against derailment of the track vehicle in twisting sections of track by calculations and to determine the existing reserves of the lifting load in the two working positions. Furthermore, the results are used in the approval process as a presentation for the technical supervisory authority (TAB).

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