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Fact sheets

PROSE ApS

Struergade 16
2630 Taastrup
Denmark

Banedanmark - Audit of the onboard ERTMS

As part of the national ERTMS rollout of the new signalling systems in Denmark the rolling stock will be equipped with ETCS. The Onboard project entered the critical time phase of equipping the required vehicles by spring 2016.

Project specification

As part of the national ERTMS rollout of the new signalling systems in Denmark the rolling stock will be equipped with ETCS. The Onboard project entered the critical time phase of equipping the required vehicles by spring 2016. The rollout is expected to be finished in 2023 with all lines in operation and about 700 vehicles retrofitted with the ERTMS signalling system.

Banedanmark entrusted PROSE with the preparation of an independent Technical Audit of the ERTMS onboard project in order to reach confidence of readiness for the fitment phase. Special focus was to be on the vehicles required for the commercial operation of the early deployment lines.


Our approach

The expert team conducted the audit in less than three months. It involved the project supplier Alstom, four railway undertakings, the NSA (Trafikstyrelsen), the G-ISA and Banedanmark.

After gaining a general overview, the following areas of subject were investigated in depth:

  • Installation plan: Is the Installation Plan realistic?
  • Installation design: Review of the technical installation design.
  • Prototype installation: Review of the existing prototype installation.
  • Approval process: Review of the overall approval process.
  • Open design issue: Assess three design issues and related solutions under discussion.


About 30 interviews were held, 140 documents were analysed and all existing prototype installations and five workshop sites were surveyed to gather information. PROSE created appraisals as per each investigated domain and compiled a comprehensive list of recommendations.


Customer benefit

Banedanmark got an independent opinion about the technical readiness of the onboard project before entering the fitment phase of vehicles. With the list of recommendations the onboard project is able to optimise the current technical performance, reduce the known risks and speed up the progress. Moreover, the future decision making can be based upon these findings.

Project information

Customer: Banedanmark (BDK), Denmark

Project data ERTMS signalling programme Banedanmark:

  • Replacement of all signalling on the railway network with ERTMS by the end of 2023
  • Implementation of ERTMS level 2, baseline 3
  • Investment of EUR 2.5 billion
  • Banedanmark expects an 80% decline in signalrelated delays
  • Denmark has a vision to double the number of rail passengers by 2030

Project data Onboard ERTMS Banedanmark:

  • The onboard project is responsible for the implementation of the onboard part of the signalling system on Fjernbanen
  • In March 2012 Alstom won the up to EUR 200 million contract to deliver onboard equipment to 41 railway operators in Denmark and install its ERTMS onboard equipment system on up to 789 trains
Bo Heegaard Hansen

Bo Heegaard Hansen

Senior Consultant

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PROSE München GmbH

Balanstraße 73 Geb. 7
81541 München
Germany

PROSE BrakePASS - Traceable and automatically documented brake tests

For railway operation safety, the correct execution of the brake test is highly important.

Problem

For railway operation safety, the correct execution of the brake test is highly important. An essential component of this procedure is the check as to whether the brake control signal reaches all braking systems of a train. Reliability can be considerably increased through an automatic documentation of this testing step. PROSE offers a novel solution using state-of-the-art technology by means of which the reliability of the execution of the brake test can be increased.


Our solution

PROSE developed the BrakePASS system to support the operating personnel.


BrakePASS consists of three elements:

  • The BrakePASS test head is set onto the coupling of the brake pipe at the rear of the train before the brake test and remains in that position during the brake test. BrakePASS has a radio connection to the operator‘s smartphone.
  • The function is controlled using the BrakePASS app. The app receives and processes the data of the brake pipe. The operator immediately receives a check-back signal.
  • Data are transmitted via the mobile network to a database, which provides online access.

Customer benefit

  • With just a few actions, the brake test is safer with BrakePASS.
  • The handling of the train is not influenced by the use of BrakePASS.
  • The continuity of the brake pipe is automatically determined and documented.
  • With BrakePASS, the employee has additional safety to perform the brake test correctly.
  • The data are documented for later evaluation.

For further information find us at: www.brakepass.one

Project information

PROSE BrakePASS

  • BrakePASS is easy to use
  • BrakePASS is attached to the rear of the train during the brake test
  • Operation takes place using the BrakePASS smartphone app
  • BrakePASS detects, when the brake pipe is not thoroughly coupled
  • BrakePASS app displays the result
  • The log is transferred to the database
Ulrich Kleemann

Ulrich Kleemann

Principal Engineer Brake System

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PROSE AG

Zürcherstrasse 41
8400 Winterthur
Switzerland

Gauge-Changing Bogie - EV09

The Montreux-Berner Oberland-Bahn (MOB) entrusted PROSE with the design of gauge-changing trailing bogies.

Project specification

The Montreux-Berner Oberland-Bahn (MOB) entrusted PROSE with the design of gauge-changing trailing bogies. The development engineers used MOB’s construction and operating principle, which makes it possible to change the gauge of the bogies by letting them run over a fixed axle-gauge changeover facility at low speed, as a basis for the design of the bogies. The change from meter gauge to standard gauge and vice versa is facilitated by two half frames, which can be slid 435 mm sideways relative to each other and which are equipped with independent wheels. This construction principle was to be realized concretely. Further challenges for PROSE were the compensation of the different platform heights for standard gauge and meter gauge by way of two supports of different heights in the bogie traverse as well as the customer’s requirement that it had to be possible to fit the new bogies under existing carbodies and under new carbodies.


Our approach

During the design phase of the bogies PROSE performed structural analyses, calculated the running dynamics and analysed different alternatives to optimise the components and the bogies. Wherever possible, PROSE’s engineers used components proven and tested by railways such as air spring and vehicle antiroll bar to minimise the risks that are generally inherent to new developments. If this was not possible, e.g. in case of the axle-gauge changeover facilities, PROSE used positively driven mechanisms such as trunnions and positive interlocking devices. By preferring simple mechanisms and standard components, PROSE was able to reduce the number of spare parts to be stored and thus reduce the maintenance costs. The bogies were developed in close collaboration with the MOB. PROSE defined the design requirements for the axle-gauge changeover facility by way of computer simulations and calculations and MOB constructed it.


Customer benefit

Thanks to the innovative gauge-changing bogies it will be possible for MOB’s passengers to drive with the GoldenPass trains between Montreux and Interlaken without have to change trains at the positions at which the track changes its gauge. Thus, the offer and the attractiveness of the line are improved, which has a positive effect on the tourism in the Berner Oberland and at the Vaud Riviera. The passengers benefit from the new services and enjoy higher ride comfort.

Project information

Customer: Montreux-Berner Oberland- Bahn (MOB), Switzerland

Operator: MOB, Switzerland

Project tasks:

  • Structural analysis
  • Simulation and anlysis of running behauvior
  • Detailed manufacturing design
  • Air spring and vehicle antiroll bar tests

Technical data for the bogie:
  • Operational service from:
  • 2017 with 54 coachesv
  • Track gauge: 1000 mm and 1435 mm
  • Max. speed: 100 km/h
  • Axle load: 8 t
Christoph Gyr

Christoph Gyr

Sales Director

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PROSE München GmbH

Balanstraße 73 Geb. 7
81541 München
Germany

New suspended monorail vehicles for Wuppertal

The suspended monorail of Wuppertal and its vehicles are
an integral part of Wuppertal’s cityscape and its cultural
heritage.

Project specification

The suspended monorail of Wuppertal and its vehicles are an integral part of Wuppertal’s cityscape and its cultural heritage. By running above the river and the streets, the suspension railway acts as a central artery of public transport in the whole city. The 31 new vehicles are to replace old trains that have reached the end of their service lives. The general contractor Vossloh Kiepe entrusted PROSE with the comprehensive mechanical design and the system integration of the new vehicles. PROSE was confronted with two main challenges: firstly, the new vehicles for the suspension railway had to be compatible with the existing infrastructure, which imposes extremely restrictive maximum values for the dimensions and weight of the vehicles. Secondly, the new vehicles had to fulfil the passengers’ requirements for modern comfort. Thus, comfort features, such as passenger information system and air conditioning, had to be integrated.


Our approach

In order to overcome the first challenge of creating the optimized vehicle for this particular application, PROSE developed a vehicle body that is assembled from aluminium extrusion profiles. By implementing this combination, the end vehicle body only weighs 5.4 tons, including the driver’s cab. The fact that all four bogies have two-stage suspensions and are powered by three-phase asynchronous motors guarantees smooth running. Through the use of regenerative braking systems PROSE is able to achieve high energy efficiency and low wear and tear. To meet the passengers’ comfort requirements, PROSE implemented a continuous row of windows conveying a dynamic appearance, which offers a bright and comfortable ambience to the passengers. Another highlight is the fullheight panoramic window at the back end of the vehicle. Moreover, the continuous low floor and wide-opening doors guarantee efficient passenger flow. The new vehicles for the Wuppertal suspension railway also offer high driver comfort: an ergonomically designed driver’s cab is separated from the passenger compartment by a transparent wall and equipped with modern touch-screen commands.


Customer benefit

Not only is the compliance with significant standards of fundamental importance for the successful realization of this unique system, but also the ability to contribute to the definition of these standards, to proactively propose an optimal solution, discuss it constructively with all parties involved (including the end customer, safety authorities and suppliers of systems and components) and finally implement it. Given PROSE’s extensive experience in developing mainstream and special projects of all kinds, PROSE’s development team was able to successfully meet Vossloh Kiepe’s expectations. Furthermore, PROSE’s intercultural experience and capabilities are highly appreciated, playing a fundamental catalyst role in the current manufacture of the vehicles in Austria, Germany and Spain.

Project information

Customer: Vossloh Kiepe, Germany

Operator: WSW mobil GmbH, Wuppertal, Germany

Project tasks:


  • Mechanical design of carbody, vehicle interior and running gear
  • Mechanical system integration
  • Manufacturing supervision
  • Homologation management

Technical data for the running gear:

  • Operational service: Trail runs as from February 2016
  • Max. speed: 60 km/h
  • Axle load: 5.7 t
  • Power output: 75 kW
Joachim Ebmeyer

Joachim Ebmeyer

Business Unit Manager München

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PROSE AB

Hamngränd 6
72130 Västerås
Sweden

The world’s first biogas-driven train

The biogas supplier Svensk Biogas wanted to prove that a train can run on biogas (methane gas).

Project specification

The biogas supplier Svensk Biogas wanted to prove that a train can run on biogas (methane gas). The customer supplied a diesel train to be converted into biogas propulsion and entrusted PROSE with the management of the development of the first biogaspropulsion train in the world from A to Z.


Our approach

PROSE was in charge of the project management throughout the project. Firstly, a feasibility study was conducted in order to identify the technical requirements, to define the project schedule and to fix the budget. Then a safety analysis was performed to identify suitable traction motors for the fuel system and a solution that fulfils all safety requirements. PROSE successfully overcame the challenges such as the limited space available for the fuel tanks and the compliance with demanding safety requirements. The existing control system was adapted to the new biogas engine and several safety features were integrated into the system. Moreover, PROSE made a test plan and tested and verified all critical parts of the propulsion system for successful commissioning of the train. PROSE prepared the technical documentation needed for the homologation of the vehicle, the installation instructions, the maintenance documentation as well as the training of the drivers and the maintenance staff. PROSE finally performed a study for the maintenance workshop for the additional safety installations and checked the results before the biogas train was put into service.


Customer benefit

PROSE supported the customer along the whole process, from the feasibility study and the identification of the technical requirements through the adaptation of the existing engine to biogas to the homologation management and the maintenance optimisation.

Project information

Customer: EuroMaint Rail, Sweden

End customer: Svensk Biogas, Sweden

Project tasks:


  • Feasibility study
  • Development of a biogasdriven train
  • Modification study for a workshop
Peter Meilgaard

Peter Meilgaard

Director Business Development

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PROSE SRL U.

Via G. Impastato 1
56122 Pisa
Italy

NAP6S electronic unit for passenger alarm system management

Project specification

In case of danger the passengers of a train can use an emergency handle to stop the train. This traditional approach can lead to the hazard that passengers cannot be evacuated if the train stops in a tunnel or on a bridge. In such a situation it is better to leave the tunnel or the bridge before the train is stopped, even in case of an emergency on board (for example fire). Therefore, an electronic device was needed that manages the passenger alarm system in the following way: When the train is in a station, the system acts in the traditional way; when the train is outside the station, activation of the emergency handle does not immediately initiate stopping of the train, but allows the driver to override the activation of the emergency handle. SEPA, was already involved in the modification of the Trenitalia Semipilota IR 3a series coaches and needed an electronic device to manage the passenger alarm system. As it was the first time that Trenitalia wanted to install a device in accordance with UIC leaflet 541-6 on its coaches, the customer needed PROSE experience with railways and electronics to design the device and its train interfaces. Therefore, PROSE designed the NAPS6 in accordance with EN 50155. Its safety-related functions are realised with dedicated self-diagnostic circuits to avoid any faults against the safety.


Our approach

PROSE studied the normative UIC leaflet 541-6 and participated in the meetings with the final customer, Trenitalia, and the vehicle manufacturer, AnsaldoBreda, to understand their needs. Thereafter, PROSE designed the electronic unit and its interfaces to the train circuit. Once the prototype of the electronic unit was ready, PROSE installed it on the train for field tests and obtained the homologation from the RINA assessor. Then the production of the NAP6S began and the unit was installed on all Trenitalia Semipilota IR 3a series coaches. PROSE made the acceptance test as well as the software load and the configuration for each NAP6S delivered. Moreover, PROSE were in charge of the training courses about functionality, installation and maintenance of the NAP6S for the AnsaldoBreda and Trenitalia technicians.


Customer benefit

To the customer, PROSE was both railway consultant and electronic designer. The extensive experience with rolling stock engineering enabled PROSE to study the standards and participate in the system design review with Trenitalia right from the beginning of the project. As a consequence, PROSE was able to design the electronic unit because they‘re were also strongly involved in the system design.

Detailed information


Customer:

SEPA, Italy

End customer:

Trenitalia, Italy


Project tasks:

  • System design of a passenger alarm system in line with UIC leaflet 541-6
  • Development and engineering of the NAP6S
  • Electrical integration of the NAP6S into Semipilota UIC-X Trenitalia coaches
  • Manuals and training courses for maintenance staff
Federico Dami

Federico Dami

Principal Hardware Engineer

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