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With the mobile twist test facility, the twist properties of the bogie and the coach body are measured. Thus all the important parameters that influence safety against derailment through wheel climb on the rail are recorded. The mobile testing facility was developed by PROSE AG and optimised to such an extent that a minimum test outlay could be achieved. Numerous tests have indicated that the test procedure is more feasible using the mobile twist test facility than conventional methods due to the ease of measurement. Furthermore, it is distinguished by the fact that it can be used flexibly, regardless of location. At the same time, the wheel loads are recorded using load cells under the axle bearings and the required measurement variables are calculated in real time during the measurement. This simplifies both the visual representation and the assessment of the results on-site.

Relying on standardised models the sound pressure levels of the impacting noise can be obtained in relation to the distance of the sound source. These calculation programs for instance are employed for noise map calculations as a part of noise protection schemes within urban planning projects.

For predicting the external noise generated by rail vehicles PROSE recently uses the new “CadnaA” program by Datakustik. This program does not only allow the virtual arrangement of different sound sources along the vehicle’s shape, but also maps the ambience conditions of the noise tests considering the effects of sound reflection and absorption.
The noise emission data for each of the sound sources either are provided by the vehicle manufacturer or are generated by PROSE based on their long lasting experience in this area and also on the use of the well-known “sonRAIL” tool. Thus noise emission values for rail vehicles can be calculated according to EN ISO 3095 in relation to the requested mode of pass-by and standstill operation.
Apart from the reference track sites according to TSI Noise also any other kind of environment can be investigated , e.g. inner city surroundings in the case of LRV or Tram systems, operation on bridges, on elevated track, along sound barriers, or in the vicinity of marshalling yards.

In addition PROSE can process complete noise maps employing the “CadnaA” program. These maps comply with the EU environmental noise directive 2002/49/EG or with the corresponding national regulations for rail infrastructure.

The new test bench allows the precise application of calibration forces to the wheel set and is prepared for different load cylinder configurations. Lateral, vertical and also tangential forces can be applied. With the new test bench it is possible to calibrate wheel sets with diameters from 350 to 1500 mm and from 760-mm- to 1680-mm-gauge. For rapidly and safely installing and removing the wheel sets, the test bench features an integrated crane, thus no other hoists are needed.

Vossloh Kiepe will develop the electrical part and manufacture the vehicles. PROSE, as engineering partner of Vossloh Kiepe, is responsible for the entire mechanical development, consisting of the vehicle body, the vehicle interior and the running gear.
The work includes the design, development, manufacturing support and placing into service, as well as the responsibility for obtaining the approval. Involved in the project are the two PROSE locations in Munich and Winterthur.
The existing vehicles have already been constructed very lightweight. The new suspension railway vehicles will additionally be equipped with a passenger information system and a light air-conditioning system. PROSE is thus challenged to design the structural vehicle body extremely lightweight, since the load of the elevated guideway is not allowed to be higher than it is today. The assignment is of great importance for PROSE, as it is the first time PROSE is responsible for all areas of vehicle construction. By choosing only one engineering partner the number of interfaces for the customer is reduced to a minimum. This reduces the project risk. In particular it also simplifies the project management and with tailored passenger friendly vehicles it will further increase the popularity of the Wuppertal suspension railway – already today an average of 87,000 passengers is transported on weekdays.

Therefore, PROSE performed an internal training day on 3rd November 2011. Design concepts in the railway rolling stock field were discussed, concerning their properties and their advantages and disadvantages for certain applications. The current status and the development of vehicle approval requirements and processes in Europe was also one of the core topics - a complex field which is in a fast change process. This led to lively and fruitful discussions. Finally, practical aspects were putted forward by doing group work on some of the themes. Last but not least, the evening before the training day, the occasion was taken to visit the collection of French impressionists in the museum Oskar Reinhart in Winterthur. A dinner completed this day and enabled a lot of opportunities to be in contact within employees of the different sites of PROSE in Winterthur, Berlin and Munich. They often work together, but see each other rather seldom. Therefore, this get-together was enjoyed and intensively used.

Before the operation of the vehicles in Germany they were modernised and adapted to the DB standard. The renovation of the vehicles lead to the necessity of a new approval, as the adaptations to the vehicles are great. The approval was obtained in Switzerland by the Bundesamt für Verkehr [Federal Office for Traffic] (BAV) and with the "Cross Acceptance", or the mutual recognition of approvals, the vehicles received the operating license for Germany from the Deutsches Eisenbahn Bundesamt [German Federal Office for Railways]. PROSE was commissioned by SBB with the process management for the acquisition of the approval. We thus functioned as an interface between the approval authority and industry / railway operators and among other things produced the necessary application documents for the BAV (schedule, application for approval, list with vehicle numbers etc). The entire dossier with all of the documents for the approval was compiled by PROSE.
Thanks to PROSE's experience with approvals in Switzerland and international deals (Cross Acceptance and RIC), this simple and quick path was able to be suggested and new ground was able to be broken by the customer. Thus, the vehicles were able to quickly go into operation in Germany.

PROSE is instrumenting the roller rig with its measuring wheelset technology in order to measure the forces acting in the contact point between roller wheels and wheel set at speeds up to 500 kph in all three directions (axial, radial and tangential).
PROSE instruments the roller rig and delivers a standard measuring wheel set as well as the necessary signal transmission devices to RENK. Additionally a software library for the evaluation of the strain gauge signals and the calculation of the forces is supplied.
PROSE AG in Winterthur is designing also a bogie half-frame to suspend the axle in the roller test rig.

Aim of the tests was to create the basis for a Europe-wide approval.
For the first time the new version of the UIC 518, and the TSI for locomotives and passenger rolling stock were implemented. The new version of the UIC 518 allows type tests to be performed on only one single rail inclination and to use these results for other rail inclinations. Prerequisite for the validity of the results is that tests are performed on sections with various types of wheel-rail contact, which is realized by driving on sections with different track profiles. In Switzerland such sections are available in close proximity of each other, allowing all the necessary tests to be carried out in one measurement campaign.
The running behaviour type tests were performed according to the normal measurement method of the EN 14363, where, as required be the new version of the UIC 518, additional evaluation parameters were taken into account.

The aim was to be granted approval for use in Switzerland. Before conducting proper type tests, test specifications were prepared which defined the tests and measurements as well as the analysis and documentation of results. A complete track test according to EN 14363 standard was specified. For the determination of the wheel/rail forces, the test specimen was fitted with measuring wheelsets which PROSE was able to provide. This therefore meant that no additional costs were incurred for customer for the use of measuring wheelsets. Furthermore, runs in switches and track journeys were carried out, the latter to measure the natural frequencies and the absorption rates of coach vibrations using wedge tests. Loading and unloading the coach with weights corresponding to passenger loads was also organised by PROSE.

The coaches have already been used by passengers since spring. This was able to take place shortly after the test runs and their initial assessment.

The Helsinki public transport network (HKL) is ordering 40 three-part trams from the Finnish railway vehicle manufacturer Transtech OY with the option of supplying 90 vehicles in total. The first vehicles are supposed to start trial operation at the end of 2012. PROSE is responsible for the vehicles' running dynamics design, bogie design and strength analysis of the bogie's structural parts. 

The vehicle design is particularly demanding as the tracks in Helsinki are subject to major shifts due to the ground freezing and thawing. The track bed is therefore worse than for example in Central European cities and the demands on the suspension system and axle location are higher than usual. We therefore have to take into account the harsh Finnish weather conditions right from the start of bogie construction. For the engineering department it is a challenge to develop a bogie that is protected from derailment, runs stably and also guarantees travelling comfort with poor track beds.
The vehicles are low floor between the bogies in the door areas and with the bogies the centre aisle's floor is only just above the wheelset axles, therefore the clearance for the bogies is very restricted. Integrating the drive unit and any other components into the bogie are the second challenge.

The examinations have already been completed and the results are known: Therefore, we can congratulate him on passing the apprenticeship examination with the very good mark of x.x! At the AZW (Winterthur Training Centre) Moritz Dennler completed the basic vocational training about theory and a founded workshop internship. In these two years, in addition to his training in modern CAD programmes he gained a broad insight into different production processes as well as in up-to-date processing methods. In the other training period at PROSE, Moritz Dennler was able to consolidate his knowledge by cooperating in various projects in the area of the development and design of railroad vehicles and to actively support our engineering team. We are delighted about the fact that Moritz Dennler will be employed as a designer after his apprenticeship here at PROSE. In addition to his occupation, as of autumn 2011 he will start studying to be a mechanical engineer Bsc, we already wish him success!

The apprentice training at PROSE offers the motivated youth a chance to step into an exciting sector. Regarding this we will gladly take responsibility and shall make a contribution towards training career starters and supporting them in the area of the engineering industry - field of railway rolling stock. In doing so it is of great importance for us to prepare the young people for an optimal entry into the working world and to offer them professional training at a high level which is pursuant to the most current standards.

As of August 2011 we once again welcome 2 new apprentices to the PROSE team:
- Carole Nef (tradeswoman; as of the 1st year as an apprentice)
- Joël Maag (designer: as of the 3rd year as an apprentice)
The basic vocational training in turn takes place in cooperation with AZW. We wish them both a good start, an exciting apprenticeship and lots of fun in the new profession!

In addition to the apprentice training we also offer interns from the field of study of mechanical engineering and electrical engineering the possibility to do a traineeship of several months at PROSE. Even within the framework of semester and Diplom (Bsc / Msc) theses, students and prospective engineers can process and research new topics in the area of railroad vehicles with us.

intend to further promote their cooperation. The CEOs of both companies, Mr. Jia Shirui and Mr. Stefan Bühler, signed the strategic cooperation agreement on June 22, 2011, in the presence of the Mayor of Jinan, Mr. Zhang Jian Guao, accompanied by a 15 member Chinese delegation, and Dr. Peter Bieri, Councillor and member of the Council of States’ Committee for Traffic. JRVEC is a large manufacturer of freight cars in China and participates in a joint venture in Poland. The Chinese Ministry of Railways plans to accelerate freight car traffic and for this reason JRVEC is increasing its activities in the sector of high-speed trains. As a provider of engineering services, PROSE AG develops coaches and freight cars, is specialized in bogies and, in its function as an accredited testing laboratory, tests rolling stock. The two companies have been working together on projects for two years. The existing cooperation is to be expanded now to better satisfy the enormous demand in the Chinese railroad market.
For the PROSE AG with its 50 employees in Winterthur, Berlin and Munich, this offers an ideal chance to continue its growth course and to contribute to the economic success of the service location Winterthur. 

The afternoon and evening programme offered met with a strong response and was accompanied by a warm and sunny spring day. The trailer bogies, where were able to change gauge, underneath the panorama wagon, which successfully took on the road from Zweisimmen to the Swiss Museum of Transport in Lucerne, were very interesting. There were many inspiring conversations and discussions about the bogie. Shortly after midday our guests could help themselves to a fine lunch buffet in the railway hall. Then there were several exciting presentations. The lectures gave our guests an exclusive and detailed insight into the development project from the origins of the gauge changing trailer bogie right up to the finished bogie. The event was rounded off with a sociable dinner.
The positive feedback from the guests shows us that once again "Treffpunkt PROSE" was a complete success and is always a popular and valued place to have an interesting conversation, find out new things about the rail industry, make new contacts and maintain existing ones.

We would be happy to make the lectures available to you:
Presentations

You can find the pictures in our web photo gallery:
http://www.byte-into.ch/prose/

We look forward to the next "Meeting Point PROSE" in 2013.

Mr. Joachim Ebmeyer as General Manager and his team complements the competence of PROSE in vehicle engineering. The core team with Mr. Ebmeyer und Mr. Butz collected considerable experience in car body design and mechanical engineering at Thyssen-Krupp with Transrapid-Projects as well as railway projects based on conventional technologies. PROSE is now in a position to offer all design and engineering tasks in relation to vehicle mechanics as car body design, system integration, interiour design, taking into account the requirements of crash behaviour, fire safety, noise behaviour as well as bogie and component design with its teams in Winterthur, Munich and Berlin. A heartly welcome to our new collegues. Together with them we are looking forward to perform challenging and interesting projects together.

MANTENA commissioned PROSE with the engineering work for retrofitting bogies with electromagnetic track brakes. Interface management was of central importance in this contract. “Interfaces” means both the mechanical, electrical and other hardware interfaces, and the project organisation interfaces between project partners. Interface management is the definition of interfaces and the coordination of partners. In this project, the mechanical, pneumatic and electrical interfaces had to be defined and the work of the supplier, manufacturer and client coordinated.

Retrofitting work was to be carried out on the bogies for the B7 passenger coach and El 18 locomotives. Engineering was relatively simple for the B7 bogies as the original design of the bogie had allowed for the subsequent integration of an electromagnetic track brake. Therefore, in addition to minor modifications to the design, focus was on verification of structural integrity according to the present state of the art.

For the El 18 bogies, however, the task facing the engineering team was more complex: the addition of an electromagnetic track brake as part of bogie refitting had not initially been planned.

Available space in the El 18 bogie was therefore closely examined to establish where and how the electromagnetic track brake could be fitted. Brake dimensions were defined on the basis of the installation space calculated; brackets to hold the electromagnetic track brake were subsequently designed and dimensioned on the bogie frame. Interfaces between the electromagnetic track brake and vehicle body for the pneumatic and electrical lines had then to be agreed with the client, and the additional pneumatic and electrical lines required for operating the brake designed on the basis of this consultation. A structural fatigue analysis was carried out on the attachment points and bogie frame once the construction was completed. These tests took account of the load produced upon braking and the load created by vibration of the electromagnetic track brake – for example during locomotive acceleration.

Calculation of noise emission with individual vehicles (figure 1):

Detailed examinations for individual vehicles can be performed by changing the parameters speed, wheel and rail roughness, type of track system and vehicle, traction and equipment noise as well as further detailed parameters (contact filter, transfer functions). For all values, the user is provided with standard values for typical vehicle and rail track types. Furthermore, manual entry of user-specific figures, e.g. measurement values of wheel and rail roughness spectres, is possible. Calculation of noise emissions when running through curves, through turnouts or over bridges as well as consideration of flat spots are also possible.

Calculation of noise emission at track sections (figure 2):

Configuration of up to 30 different train compositions allows for emission calculation at whole track sections. The vehicle types and the number of coaches in a train set as well as the number of trains per assessment period and their speed can be freely selected. Wheel roughness, number of axles as well as the percentage of axles with flat spots can be defined for each vehicle within a train set. The calculations can be performed for various rail roughnesses and track system types.

laboratory measured the forces between the wheel and rail using single measuring wheels. The innovative chassis with transversely sliding half-frames and idle gears, required the use of single measuring wheels instead of a measuring wheelset, which presented the PROSE engineers with many new challenges.

Great importance was placed on the reliability of the measurements and the accuracy of the results. The PROSE single measuring wheel system consists of 2 single measuring wheels with signal transmission per wheel and a measuring wheelset data processor. The single measuring wheels are therefore used to measure the deformation of the wheel disc using strain gauges. The signal amplification and transmission takes place in the hollow bore of the shaft of the single wheel. The signal transmission takes place optically as a serial data stream. The measuring wheelset data processor calculates the forces between the wheel and the rails as well as other factors from the measured wheel disc deformation.

Aside from meeting technical measuring requirements, the following conditions also have to be considered. In the metre gauge, there is limited installation space for the measuring equipment between both inner single wheel bearings. Furthermore, the small diameter of the shaft in relation to the hollow bore only allows for the installation of small electronic components. For these reasons, special components for electronic amplification had to be developed. In order to calibrate the single wheels to a conventional measuring wheelset, the single measuring wheels also had to be combined with newly constructed fixtures force-closed to an 'axis'. Moreover, special adaptable parts had to be produced for the installation of single measuring wheels and the accompanying fixtures to the track change bogie.

The operating technology measurements on normal and metre gauge track sections were successfully carried out in summer 2010. Due to the evaluated measurement results which were documented in a report, the BAV was able to grant a temporary approval for normal passenger operation in autumn 2010, supported by the scheduled use of a test vehicle.

In order to be al-lowed to run and to work on the various infrastructure networks these grinding ma-chines have to be homologated by the respective authority of each country. “GRIZZLY 104” is currently in successful operation in Switzerland and France since many years bearing the necessary homologations. In order to be able to be engaged in Germany “GRIZZLY 104” is obliged to be homologated by the German EBA.

PROSE Ltd was mandated by Scheuchzer Ltd to organise, lead and perform the en-tire homologation process together with the relevant authorities. Not only measuring campaigns with respect to brakes, noise, vibrations, EMC and running dynamics were to be performed but a major part of the task consisted in preparing the analysis and verifications including the expertises required by EBA in all the fields of this vehi-cle. This process took several months to be completed particularly due to the fact that the vehicle was originally built in accordance with the relevant Swiss and French standards applicable at the time of its construction and manufacturing. Those stan-dards are not fully congruent with today’s EN standards.

After some nine months of intense work and negotiations with manufacturers, asses-sors and authorities EBA issued the homologation on the 22nd of December 2010 and “GRIZZLY 104” is therefore authorised to start up working in Germany.

The overall know-how and the access to the relevant specialists in the field of rail-ways enabled PROSE to manage and to conclude the process of EBA-homologation in a target-oriented and efficient manner.

Due to the rough wheel treads of older vehicles with cast iron brake blocks a lot of rolling noise is generated. By using modern composite brake blocks the wheel treads remain smooth and the rolling noise can be reduced significantly. Acousticians do describe the physical properties of sound generation and do define optimal mode of action of measures. Our expertes of rail vehicle engineering, espacially in the field of bogie design and brake systems, do devolep retrofit concepts according to customer requirements of operation. The key of successful noise mitigation is to integrate the measures as effectively as required and as simply as possible into the existing vehicle design. Hence a safe and economic operation can continue to be guaranteed.

 

 

This new electrical multiple unit class ETR 245, supplied by ALSTOM, and will be operated by the Railway Undertaking LeNord S.r.l. It is designated as CSA (Convoglio Servizio Aeroportuale) and will transport the passengers to the airport of Milano Malpensa.

Purpose of these extensive tests is the proof of compliance of the vehicles with the requirements of the norms and regulations. This proof will be the basis for the approval and homologation of the trains by the Italian National Safety Authorities.

PROSE is in a position to expand its technical competence in Italy through the intensive collaboration with the Notified Body RINA.

The basis for PROSE's task was a basic concept with the functional principle elaborated by the operator MOB. PROSE Ltd. revised, optimised and completed the preliminary design by means of design studies, stress analysis and running dynamic simulation. This resulted in a final design with manufacturing drawings.

The innovative principle for changing the track gauge, i.e. the lateral movement of the two bogie half frames from meter gauge to standard gauge and vice versa, was analysed be means of computerised kinematic simulation and dynamic calculations. These results were the inputs for the design of the bogie and of the track gauge changing facility. MOB disposes now, apart of the two prototype-bogies, of an operative track gauge changing facility on which functional and endurance tests can be performed. The facility is currently installed at the premises of MOB in Montreux but it will be later relocated to Zweisimmen.

PROSE Ltd. achieved a further milestone in its key competence in bogie design by the successful completion of this development project for the track gauge changing bogie for MOB.

PROSE Ltd. is an engineering company in the field of railway rolling stock with about 40 employees, performing running dynamics and structural analysis, designing refit projects, performs vehicle testing as accredited testing laboratory and consults in the field of noise reduction, procurement management and maintenance optimisation.

 

Click here for a video of track gauge changing (M4V, 30MB)

 

 

 the motor bogies for the diesel-electric locomotives Gmf 4/4 for the Rhaetian Railways (RhB).

The 4 ordered locomotives shall be in operation in the infrastructure department of RhB, mainly used for heavy track construction and maintenance trains as well as trains to remove snow from the track.

The bogies have to satisfy the high requirements of lines with a lot of narrow curves of the RhB lines in the Swiss Alps as well as to run with 100 km/h. In addition special attention has to be paid to a reliable operation also under strong winter conditions.

PROSE develops with 40 employees bogies, performs running dynamics and structural analysis, designs refit projects, does vehicle testing as accredited testing laboratory and consults in the field of noise reduction, procurement management and maintenance optimisation.

 

We tested the vehicle concerning running dynamics, brake and wheel slide protection system intensely.
 
PROSE already tested vehicles of the same platform before in the Netherlands and in Switzerland which achieved the national homologation. The accredited testing laboratory of PROSE has the necessary specialist knowledge and the experience, which is required for the homologation of such special vehicles.

With the goal to offer our customers even more complete service out of one hand, we enlarged our portfolio per January 1. 2010. With the acquisition of the laboratory for interference currents tests from Bombardier Transportation (Switzerland) Ltd we now are able to also measure and document this important parameter of a vehicle accordingly. With Herbert Biri and the needed [Ueli Ritter] testing equipment for this specialized department, we now cover together with the existing testing laboratory, the range from measuring brake performances, comfort levels, noise, ride quality and security to interference current needed for the homologation. Our customers can now obtain these services from a single source of PROSE.

To be ready for the needs of the re-emerging market, we are expanding by February 1. and March 15. our engineering team in the field of strength analysis and running technique with two experienced engineers, who have a wide experience in the development and design of freight wagons. For our design team, we were able to win with Gregory Völkening a professional with many years of experience in the management of engineering projects. Thus we have those skills necessary to to be able to.quickly and comprehensively respond to the requests and needs of our customers.

We extensively tested the train in driving comfort and running dynamics, in the
pleasant environment of the "Bündner Mountains". These studies are an important step
in the delivery and commissioning of this new train. We also support your prject on the
home straight.

... and aerial cableway and tunnelling equipment under one roof. 

Visitors to suissetraffic could find a very varied programme with a representative cross-section of current innovations from all sectors of public transport. Over 160 exhibitors occupying 20,000 m2 of space, fascinating conferences and a well-supported Symposium made suissetraffic this year's central market platform in Europe.

PROSE's stand - The exhibition opens soon ... 

Panel discussion with our CEO Stefan Bühler

... we made the step to Germany. Thus you have shorter ways to the well-known achievements of the PROSE Ltd. At the location in Berlin we will offer in particular our services in Measuring and Testing.

www.prose-deutschland.de

...our customers and business-partners.  Our presentations, one example and solution of each of our departements, have shown the wideness of the business activities of PROSE and fulfilled the expectations at all. The customer event 2009 was rounded by the fascinating performance of the "Freilichtspiel: Das 3. Gleis“ in the evening. Just great! 

Download of handouts:

- Measuring & Testing: TSI-Environment

- Change-Management: "Everything is in a state of flux"

- Engineering & Consulting: Damage-Analysis

- Noise & Environment: Railway-Noise-Mitigation

Please find here a selection of:

- Pictures of the event 

PROSE has successfully achieved the certification to perform welding work within the range of certification level CL4 according to EN 15085-2.

Der neue PROSE Geschäftsbereich Noise Reduction & Environment führte im Januar 2009 erfolgreich die erste Geräuschemissionsmessung nach der Richtlinie 2000/14/EG durch.

Rechtzeitig zur Inkrafttretung der neuen Maschinenlärmverordnung (MaLV) für die Schweiz im Sommer 2009, ist PROSE bereit, die entsprechenden Hersteller solcher Maschinen mit den notwendigen Messungen bedienen zu können.

Herr Christian Czolbe freut sich, wenn er auch Ihnen helfen kann und Ihre Maschinen erfolgreich zur Zulassung führen und die notwendigen Zertifikate ausstellen kann.

The division under the lead of Christian Czolbe dedicates itself primarily to the improvement of the noise pollution of our population. Noise studies are compiled, studied environmental condition in connection with the railway and prepared solutions.