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Approval ManagementTests and
Certification
Trials
Tests
Expert opinions
Contact
DB Systemtechnik
Kolumnentitel
Foreword
1
Approval management, tests and certification
Engineering tests and trials make an important contributionto ensuring the safe, reliable and economical use of thetechnical systems deployed in today’s railway systems.
The high complexity of modern railways demands the system-wide examination of the interplay of individual componentswithin the entire integrated railway system. With their com-prehensive knowledge of railway systems, approved test pro-cedures and equipment, and proven practical expertise, thedepartments within the DB Systemtechnik test facility – oneof Europe’s leading railway engineering centres – have beendelivering these expert services for many years.
The test centre and expert organisation form part of a singlebusiness unit that is independent of DB Systemtechnik’s otherbusiness activities.
Both the test centre and the expert organisation are certifiedto DIN EN ISO 9001, and all the main railway-specific testprocedures needed for the approval or commissioning of tech-nical systems are accredited in accordance with the DIN ENISO/IEC 17 025 standard. The expert organisation fulfils therequirements specified for an inspection body and is accredi-ted according to DIN EN ISO/IEC 17 020. Both institutionsare recognised by the German Federal Railway Office (EBA)and as associated partners of the railways interoperability no-tified body EISENBAHN-CERT (EBC) they meet all the requi-rements for EU certification.
Klaus Albert BoltenHead of approval management,
tests and certification
Kolumnentitel
2
Approval/Tests Components
Certification of components/materials/working materialsLaboratory testingExpert OpinionsTSI-Certification components for interoperability
TSI-Zertifizierung Interoperabilitäts-Komponenten
Measurement and diagnostic systems
Pantograph/ catenaryCheckpointsInstrumented wheelsets
Approval/Tests Infrastructure
Approval Track Condition monitoring infrastructurePart release infrastructureTests on the trackExpert´s report TSI-Certification infrastructure
Approval/Tests Rolling Stock
Approval rolling stock Approval management Running tests Safety assessment in accordance with EC regulation 352/2009 Risk assessment (from hazard identification to risk control) Safety case Expert´s report Functional safety assessment TSI-Certification Rolling Stock
Metrology
Calibration and testingTest resource monitoringSuitability of test processesConsultancy and training for test resource monitoringDevelopment of measuring and testing methods
Our Services
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The specialised technical knowledge and the test facilitiesand equipment available at DB Systemtechnik cover theentire spectrum of railway engineering, from testing indi-vidual components to examining complex systems such asan entire high-speed multiple unit, and from assessing in-dividual incidents to compiling EU test reports of com-plete railway subsystems.
Our experienced teams of technical experts and consultantsprovide professional analyses and assessments in the follow-ing areas:
Running and vibration technologyTrack systems, vehicle/track interactionBrakes technologyDraw and buffing gear, train dynamicsTraction technology Power transmission, power supply, catenaryControl-command systemsRadio, telecommunicationsElectromagnetic compatibility, influenceInvestigations of electrical parts/componentsInvestigations of mechanical parts/componentsMaterialsFatigue strengthTribologyAcousticsAerodynamicsAir conditioning technologyMetrology
The Range of Services
High speed test vehicle
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Measurement train for vehicle response measurementsand component testing
ICE-S
The train comprises two power cars (series 410.1)and 2 measurement coaches
High-speed and upgraded lines in the networks runby DB AG and other European railways.
Track clearance in accordance with TSI rules; sche-duled inspections and partial track clearance; inter-action of pantograph and catenary in accordancewith the regulations of the infrastructure manager(DB Netz AG).
Examining vehicles in the ICE series; determining operating parameters; wear characteristics; damageanalyses.Testing of vehicle components and diagnostic equip-ment.
Wheel/rail contact forces; acceleration values onrunning gear and in vehicle bodies; contact forcesbetween pantograph and the catenary.
Train configuration:
Geographical deployment:
Use:
Parameters measured:
Tilting technology test vehicle
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Tilting technology measurement train for vehicle responsemeasurements and component testing
VT612
The train comprises the two vehicles 612 901-9and 612 902-7.
Rail networks run by DB AG and other Europeanrailways.
Scheduled vehicle dynamic testing and partial trackclearance in accordance with the regulations of theinfrastructure manager (DB Netz AG).
Examining vehicle components and diagnosticequipment; determining operating parameters;wear characteristics; damage analyses.
Wheel/rail contact forces; acceleration values onrunning gear and in vehicle bodies.
Train configuration:
Geographical deployment:
Use:
Parameters measured:
Approval management
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Approval Management
For its customers, DB Systemtechnik undertakes the ma-nagement and execution of the approval process both inGermany and abroad when it comes to approving a vehiclefor the first time or extending its area of use. This includesthe required test runs, assessments and all EC certifications.
The DB Systemtechnik inspection body offers manufacturersits involvement in the development process from an earlystage. Discussing approval and testing requirements early onallows manufacturers to optimise their workflows and signi-ficantly accelerate the approval process, especially in the case of European approvals. Years of experience in thissegment have aided DB Systemtechnik in becoming a leader inthe field of international approval activities. We are particu-larly well positioned to deal with complex test programmesinvolving several European countries.
Approval management
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We offer the following individual services:
Consulting on applicable modules in line with the TSIPlanning and managing the entire range of services re-quired for approval, the necessary testing in the lab and on track, assessments, provision of quality certificates and EC certificationsPlanning the required scope of testing in all involved countries with a view to optimising the duration of the testing and the coordination with the authorities involvedConducting any additional testing required – e.g. type tests, measuring noise emission limit values according to TSI NoiseCoordinating the required documents and reports betweenthe bodies involvedChecking the documents, reviewing quality, e.g. in the production phaseCreating documentation and assessments in test reportsExplaining the resultsPlanning and conducting the required test runs• Obtaining the required official permits, including
network access for test runs e.g. in line with TEIV (Railway Interoperability Law) guidelines
• Submitting train path applications for on-track testing• Conducting on-track testing as an independent railway
undertaking with in-house train drivers and traction units
Expert opinions and EC verification procedures
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Our experienced experts analyse and evaluate complex tech-nical material on behalf of our customers. Our customer baseincludes manufacturers of railway systems and components aswell as railway operating companies.
The service portfolio of our expert organisation includes thepreparation of inspection- and assessment-based expert re-ports of railway systems and subsystems. These expert opi-nions serve as the basis for decision-making in the followingareas:
Original approval and/orContinued operation of objects (e.g. vehicles/infrastructure facilities and/or their components) orApplication of railway operating procedures.
About forty of our experts are accredited with the German Fe-deral Railway Office (EBA). Their specialist expertise is com-plemented by extensive knowledge of railway systems, an ex-cellent understanding of railway operations and railwaymaintenance procedures.
Expert opinions and EC verification procedures
Expert opinions and EC verification procedures
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DB Systemtechnik’s test centre and its expert organisationhave been accredited with the EBA as “associated partners ofthe notified body for railway interoperability EISENBAHN-CERT” since 2001 and we have a team of experts specialisedin dealing with questions of interoperability. As part of the ECcertification process, the DB Systemtechnik expert organisa-tion conducts EC verification procedures of subsystems andso-called interoperability constituents in accordance with theTechnical Specifications for Interoperability (TSI). Our serviceportfolio covers all designated modules. We have experiencein the high-speed trains sector (e.g. ICE 3, ICE T, ICE 3 MF)and with freight wagons and their interoperability consti-tuents. EC verification procedures are also conducted in therailway infrastructure sector.
In June 2007, the expert organisation received accreditationas an inspection body. Accreditation was awarded by the Ger-man accreditation authority DAP Deutsche Akkreditierungssy-stem Prüfwesen GmbH for the inspection areas: running dyna-mics, brake technology and fatigue strength tin accordancewith the DIN EN ISO/IEC 17020 standard.
Tests and Trails
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Tests, investigations and trials make an important contri-bution to the safe, reliable and economical use of technicalmeans of production in railway operations. With eighteentest laboratories, the DB Systemtechnik test centre guarantees independent and impartial testing.
The test centre performs all the track and laboratory testingrequired for the commissioning and approval of railway tech-nical systems. All stages of the test process are covered, fromacceptance of the test vehicle through to delivery of the finaltest reports:
Planning and management of all necessary testsPreparation of the technical assessments and expert opinions required for network access and for approval by regulatory authoritiesSubmission of test schedule for network line trialsExecution of line trials as an independent train operator using our own drivers and traction units
We would be pleased to arrange testing and trials to accom-modate your own schedule.
The DB Systemtechnik test centre cooperates with partners inother countries in order to provide a broad portfolio coveringcommissioning and approval services not only in Germany,but in other European countries as well.
Tests and Trials
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Tests and Trials
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We are the people to speak to about tests involving brakes,draw and buffing gear and train dynamics. As a result of manyyears of experience and of modern, rail-tested instrumentation,our services are in demand by railway companies and industryat home and abroad.
In addition to our standard measuring tasks, individual solutionsare developed, such as providing support for the instrumentationof field trials. Measuring carriages are maintained for operationaltests; a pneumatic testbed, a skid simulation testbed, a UIC-approved friction testbed and a component lining testbed areavailable for testing brake components. Our facilities alsopermit comprehensive and complex trials to be carried outinvolving large numbers of measuring points.
The tests listed below are an extract of the range of serviceswe provide, and are accredited in accordance with DIN ENISO/IEC 17025:
Testing the braking equipment of railway vehicles for acceptance in accordance with EBO or TSIDetermination of the braking capacity (brake assessment)Anti-skid testing on the vehicleTesting the capacity of railway vehicles to cope with steep inclinesDetermining the thermal performance of brakes on downhill sectorsInvestigation of the dynamic behaviour of railway trains
Brake Technology
Tests and Trials
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Testing components of the braking equipment (brake controllers, anti-skid components, magnetic rail and eddy current brakes, sand distributors, emergency brake bypass/electro-pneumatic brake equipment) for UIC or EC approval, and as demonstration of fitness for railway useTribological testing of brake shoe inserts, brake lining, brake discs and wheels for UIC or EG approval, and asdemonstration of fitness for railway useDraw and buffing gearField trials on componentsThe determination of cumulative operating stress using data loggers
T.TVI 12 Sebastian HeinzPionierstraße 10, 32423 Mindenphone +49 571 393-5425, fax +49 571 [email protected]
Tests and Trials
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The experimental groups are specialized in carrying outengineering tests on running and vibration in railway vehicles.In addition to modern, railway-tested instrumentation equip-ment, the groups possess comprehensive expertise in theengineering investigation and evaluation of railway vehiclerunning. This capacity has been exploited and valued foryears by both internal and external customers – the railwayindustry and railway operators.
The trials listed below are only an extract from the rangeof services:
Vehicle-dynamic testing of railway vehicles (approval testing)Continuous rail profile measurement Engineering optimisation trials (testing of components and assemblies)General vibration testing of railway vehiclesVehicle response measurements for track clearance procedures and scheduled inspections (vehicle-track interaction)Wheel and rail profile measurements and profile optimisation Radial runout and wheel diameter measurementsMeasurement of coefficient of tilt (roll angle)Measurement of mechanical turning resistance (on special test rig) and examination of smooth action of bogies and running gearDemonstration that small wheels will not derail when negotiating gaps in curved crossingsDetermination of track twisting strength (on special test rig)Determination of wheel/rail contact forces and wheel force tolerances on the track-twist test rigDemonstration of safe negotiation of twisted tracks (twisted track curves)Determination of lateral and longitudinal stiffness curves and lateral and longitudinal dimensional play of vehicles (test rig with lateral-pressure measuring equipment)Determination of guidance forces and rail/wheel contact forces on a curved test track (radius: 150 m)Measurement of flange angle of attack
Runnning Technology
Tests and Trials
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T.TVI 23 Thomas KolbePionierstraße 10, 32423 Mindenphone +49 571 393-5426. fax +49 571 [email protected]
Determination of guidance forces and rail/wheel contact forces on acurved test track (radius: 190 m)Production of measurement wheelsets (for measuring forces and stress loading)Manufacture of Q-force measurement blocksCalibration of measurement sensorsDevelopment of diagnostics systemsConsulting services in the field of data measurement and analysisAdvisory and support services during the approval processCompilation of expert reports in the areas of vehicle dynamic testing and vibration testing (several members of the department are EBA-accredited technical experts)
On top of this, the division has command of comprehensiveknowledge in the manufacture of instrumented wheelsets –from application through to signal transmission and calibration.
As well as the wheelsets for force measurement, of whichwe have made so far more than 400, what are referred to as"loading measurement wheelsets”, which provide figures onthe local loading of wheelsets, are made. It is also possible forcombinations of the two measuring procedures to be imple-mented on one and the same wheelset.
Tests and Trials
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The ever increasing demands being placed on today’s railwaytrack systems – higher speeds, higher axle loads, increasedvolumes of rail traffic – require the continuous developmentof innovative solutions that have to be tested before they canbe implemented. The “Track system and vehicle/track interac-tions” group is organised so that it can provide all track-rela-ted measurement services. The group is fully accredited andoffers a complete range of track measurement services fromthe application of foil strain gauges for measuring strains andforces to the measurement of wheel out-of-roundness or thetensile forces operating on switch drive rods.
Overview of the group’s service portfolio:
Fundamental examination of track componentsMeasurements to verify compliance with the applicable technical specifications and regulations; review and updating of standardsInput data for life cycle cost estimates and computational models
Long-term measurements of permanent way componentsMeasurement of quantities that change slowly (i.e. over hours or days), measurements on rail expansion joints and curve breathing
Measurement services to accompany the introduction of new per-manent way components and construction procedures
Measurements during operational testingAssessment of the efficacy of new elementsExample measurements: levelling, subsidence, cavities and voids, resistance to transverse displacement of track, rail profiles, longitudinal rail section profiles, etc
Support services during the introduction of new technologyData interfacing, incorporation into existing infrastructure,requirements documents, maintenance conceptsEquipment for detecting out-of-round wheels, vehicle-data recor-ding stations, rail-temperature monitoring stations, track balances and sensors on gauge-changing facilities
Track Technology
Tests and Trials
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T.TVI 23(4) Jörg Michael ReineckePionierstraße 10, 32423 Mindenphone +49 571 393-5208, fax +49 571 3 [email protected]
Supplementary vehicle approval servicesStudies on a curved crossingStudies on curved sections of track with a radius of 190 mMeasurements of wheel/rail contact forces and guidance forces
Vibration measurementsMeasurement, analysis and documentation of vibrations in components of railway traffic routes Measurements performed in accordance with the DIN 45672 standard
Investigation of irregularities that could endanger railway operations
Objective and independent determination of the relevant parametersDocumentation of current state
Measurement of operational loading scenarios on track components
Field measurements to determine the stresses experienced by track componentsStudies to determine the effects of altering operational conditionsExample measurements: force measurements, strain measurements, distance measurements, track load metering, etc.
Tests and Trials
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Laboratory tests and operational trials related to fatiguestrength, structural mechanics, structural dynamics and thefunction of mechanical components are offered, as are factorycalibrations of force sensors. As a competent authority accre-dited by the German Federal Railway Office, we compile expertreports on the service strength of wheels, wheelset axle shaftsand wheelsets, coach bodies and bogies as well as reports onthe collision safety of railway vehicles.
The services listed below represent only a fraction of thegroup’s portfolio:
Accredited approval testing for wheels and axle shafts, bogie frames, coach bodies and side windowsOperational measurements to analyse service loading, to determine design loads and to verify the dimensioning and engineering design of railway system components (e.g. analysis of bogie frames in accordance with the EN 13749 standard)Static strength verification for rail vehicles (pressure tests), dynamic testing of vehicles on shunting humpsFunctional testing of side windows, hydraulic dampers and tilt cylindersExperimental modal analyses and operational vibration analysesDevelopment of test campaigns and test setups to demonstrate the service strength of railway components
Fatigue Strength
Tests and Trials
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A comprehensive range of equipment with test areas, servo-hydraulic cylinders, measuring instruments for force, displace-ment, extension, acceleration and pressure, and a large numberof items for modified experimental setups permit orders tobe carried out competently and flexibly. When necessary,measurements are also carried out at the customer's site.
We can draw on our extensive knowledge of FEM calculationsand many-body simulations to dimension components or toprovide theoretical assessments of how operational conditionsaffect the component service strength.
T.TVI 24 Martin GrabPionierstraße 10, 32423 Mindenphone +49 571 393-5580, fax +49 571 [email protected]
Tests and Trials
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The demands both for high travel speeds in great comfort andfor achieving the highest possible environmental compatibilityat the same time mean that the sound emission associatedwith railway traffic is becoming an increasingly important issue.For decades, the experts at DB Systemtechnik have been apply-ing scientifically obtained knowledge to create effective mea-sures for reducing the noise associated with railway vehiclesand routes. The Acoustics and Vibrations measurement grouphas been involved with this process of optimization since thevery beginning. On the basis of all these years of experience,paired with the application of the latest acoustic measurementprocedures – some of which have been developed by the divi-sion itself and which are recognized by the EBA – the measu-ring group can offer a wide spectrum of technical sound te-sting and acceptance procedures to interested customers:
Measurement of interior and exterior noise of rail vehicles using the standardised procedures in ISO 3095 and ISO 3381.Full-range of acoustic engineering acceptance measure-ments on railway vehicles in accordance with the TSI Noise (Technical Specifications for Interoperability – Noise) The TSI measurements can be performed on several TSI refe-rence tracks that the department maintains within DB’s conventional and high-speed rail networks.Measurement of the noise radiation from the permanent way and from engineering structures, such as bridges.Development of innovative techniques for examining railway-related noise such as brake screech, curve squeal or tunnel sonic boom.Localisation of noise sources by imaging the noise-source distribution on vehicles and their components using a high-resolution microphone array (acoustic near-field holographyand beamforming)
Acoustics
Tests and Trials
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Testing and continuous monitoring of acoustic characteris-tics of rails using the acoustic measuring car, which is cur-rently the only monitoring instrument approved by the Fe-deral Railway Office (EBA) for use in the “Specially Monito-red Track” (SMT) programme. Examination of noise and vibration levels in railway vehicle workplaces in accordance with EU Directive 2003/10/EC, the German accident prevention regulations on noise abate-ment (“UVV Lärm”) and Directive 2002/44/EC.Determination of the spatial acoustic properties inside rail-way vehicles and buildings in accordance with the DIN EN ISO 3382 standard.Quantitative testing of the acoustically relevant surface roughness of rails and wheels in accordance with the DIN EN ISO 3095, DIN EN ISO 3381 and EN 15610 standards.Vibration measurements inside the vehicleVibration measurements along the transmission route in the vicinity of track installations in accordance with the DIN 45672 standardMeasurements for establishing and recording evidence of vibration immission levels in buildings in accordance with the DIN 4150 standardCharacterising the dynamic properties of track sections in accordance with the EN 15461 standard
T.TVI 32(3) Nicolas MeunierVölckerstraße 5, 80939 Münchenphone +49 89 1308-7617, fax +49 89 [email protected]
Tests and Trials
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The tasks of the accredited Aerodynamic Measurements testdivision are as wide-ranging as the large number of aerody -namic questions faced by railway operations. Every task there-fore presents new challenges to the instrumentation to beused; many years of experience and a specialized system forrecording measurements permit us to meet these challenges. The test division is authorized to develop new test procedureson its own initiative, or to extend existing procedures.
We provide the following aerodynamic measurements andservices:
Determination of train-generated aerodynamic loads (pressure, flow), for example when demonstrating the structural stability of high noise protection walls or for vehicle approval testingScientific studies designed to optimise or determine the limits for specific aerodynamic phenomena, such as avoi-dance of flying ballast or tunnel sonic boomAnalysis of damage caused by train-induced pressure and aerodynamic loads
Railway aerodynamics is not just concerned with the aerody-namic performance or response of specific components andstructures within the railway system, it is an interdisciplinaryfield that helps to guarantee the safe and efficient interactionbetween vehicles, infrastructure and operations. Aerodynamicaspects of railway operations are therefore an integral part oftechnical regulations. The “Aerodynamics” test departmentprovides documented conformity testing in accordance withthe requirements of the DIN EN 14067 standard and theTechnical Specifications for Interoperability (TSI HS vehicles4.2.6.2-4.) in the following areas:
Train-induced aerodynamic stresses experienced by rail-way workers and passengers on the platformPressure stresses caused by the train’s bow waveMaximum pressure fluctuations in tunnels
Aerodynamics
Tests and Trials
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Wind tunnel trials using model vehicles in accordance withthe DB specification RIL 80704
Example projects:Compliance testing as part of rail vehicle approval processWind tunnels studies using 1:7 to 1:15 scale models of trains to assess safety on exposure to side winds using our own internal six-component wind tunnel balanceNon-contact measurement of deflection, displacement and distortion of components of railway infrastructure under aerodynamic loading, e.g. deflection of noise protection walls during train pass-byNetwork of local static measurement points for the simul-taneous monitoring of temperature, pressure and airflow conditions over many kilometres within railway tunnels (e.g. for studying sonic boom phenomena in tunnels)Aerodynamic measurements on running trains, e.g. airflow measurements and imaging on an ICE 3 at 300 km/h, opti-misation of sander units, air inlets or chimneysPass-by of two test trains at specified locations in tunnels in order to create a critical pass-by event in which the rail vehicles are subjected to maximum pressure stresses.
T.TVI 32(3) Martin EisenlauerVölckerstraße 5, 80939 Münchenphone +49 89 1308-7530, fax +49 89 [email protected]
Tests and Trials
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The competition between transport providers means thattravellers must not only be brought to their destination safely,economically and quickly, but also comfortably.
The condition of the air in the carriage has an important effecton the sense of well-being. Since practically every car is fittedthese days with air-conditioning, passengers now expect anair-conditioned carriage even on local journeys. Air-conditioningequipment is a central, indeed essential, element in high-speed transport.
The following physical magnitudes are critical to thecomfort of passengers:
The temperature of the airThe speed with which the air is movingThe temperature of the surrounding surfacesThe relative humidity of the airChanges in the internal pressure (the level and the rate of change of the pressure inside the carriage when travelling rapidly through tunnels)
Values and tolerance ranges for these parameters are requiredin the regulations or by the European rail companies.
The Air-Conditioning Equipment Measurements division of DBSystemtechnik is able to handle all the measurements requiredin the context of these issues.
In particular, this includes:
Functional tests on air-conditioning and heating equipment, and on component parts to minimize risks in advance of the actual type testing in the climate-controlled test chamber
Air Conditioning Systems
Tests and Trials
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Complete type testing of the air-conditioning comfort and equipment, in accordance with all common regulations or with performance specifications, in a climate-controlled test chamberFunctional investigations and measurements of air-conditioning comfort while travelling under operating conditionsSupport for instrumentation in questions of the repair and servicing of air-conditioning equipment (e.g. filter change intervals, soiling problems)Providing assistance in matters of redesign and modificationof old trains (fresh air supply, replacing old components)Measurement and assessment of the pressure comfort during tunnel transits, and determining the pressure-sealingof the vehicles used for high-speed transport, plus stationaryleak-finding
T.TVI 32(3) Michael MeisterPionierstraße 10, 32423 Mindenphone +49 571 393-5521, fax +49 571 [email protected]
Tests and Trials
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The division offers services for verifications and for trials, bothout on the track and in the laboratory, in the field of tractiontechnology. A tribological laboratory, mobile measuring equip-ment (measurement carriages), and a pantograph test labora-tory are available for this purpose. Several of the division'semployees are qualified to prepare expert opinions for the Fe-deral Railway Authority, and are recognized as qualified expertsby the EBA, in the fields of the interaction of the pantograph,the catenary and tribology. The key test procedures are accre-dited in accordance with the DIN EN ISO 17025 standard.
The services listed below are an extract from the range ofthe division's work:
Investigations of the pantograph/catenary system for the acceptance of railway vehicles concerning national and international standardsTesting and optimizing the blending of dynamic and pneumatic brakes on locomotives and multiple unitsContinuous charging and cycle tests on batteries for railway vehicles and for stationary railway equipmentInvestigations of vibration in the drive train and on particu-lar vehicle components in multiple units and locomotivesPower consumption measurements, optimization of anti-skid and anti-spin protection, and the preparation of traction and braking force diagrams to verify the per-formance specifications of locomotives and multiple unitsProving and examination of the compatibility of power supply systems in passenger carriages and locomotives with diesel locomotives.
Traction Technology
Tests and Trials
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Investigation of the on-board DC networks on railway vehicles and stationary railway-specific systemsPhysicochemical and tribological investigations of lubricants to assess extent of wear and to establish inspection intervals
The department also has extensive knowledge and expertisein manufacturing, deploying and calibrating contact-forcemeasuring systems for pantographs. This technology is useddomestically and abroad for determining the contact forcesbetween pantographs and catenaries.
T.TVI 33 Dr.-Ing. Frank RickVölckerstraße 5, 80939 Münchenphone +49 89 1308-7460, fax +49 89 [email protected]
Tests and Trials
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The “ERTMS/ECTS” group offers expertise in product validationand product approval, quality and safety testing, and in themanagement and logistics of experimental trials. In collabora-tion with our partners and in accordance with our client’s spe-cifications, we provide advisory, planning or active support inthe implementation, approval, management and optimisationof control/command and signalling (CCS) products.
Key services include:
Functional and operational testing of systems, subsystems and components using test cases and test sequences based on requirements documents, regulations, system require-ments specifications and other product specifications.Planning and realisation of test runs, for instance, for the European Train Control System (ETCS)Design and monitoring for type approval and type testing in accordance with the Trans-European Interoperability RegulationsSupport for users and producers of command/control systems in achieving and monitoring compliance with agreed quality and safety objectives, for instance, by designing processes and by providing advisory and auditing servicesRAMS analyses (reliability, availability, maintainability and safety)Development of formal, quality- and safety-driven specification methodologies.
ERTMS/ETCS
Tests and Trials
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The “ERTMS/ECTS” group is an independent and impartialbody that provides verification and validation services in thearea of railway control, command and signalling systems. Fortrain operating and infrastructure management companies,manufacturers of CCS systems, regulatory authorities and na-tional and international committees.
T.TVI 34(1) Klaus SchaffarczikVölckerstraße 5, 80939 Münchenphone +49 89 1308-7340, fax +49 89 [email protected]
Tests and Trials
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Ensuring the safe and reliable interaction between railwayvehicles and railway infrastructure requires the interference-free and disturbance-free operation of all control/commandand signalling systems. Resolving specific questions regardingelectromagnetic disturbance, demonstrating disturbance-freeoperation, testing compliance with specified limits for electricand magnetic field strengths or interference currents are allcomplex tasks that in many cases can only be carried outusing advanced instrumental techniques.
The “electromagnetic compatibility” group specialises in testruns, stationary field measurements and test lab studies in thelow-frequency range up to around 100 kHz (traction currentand drive systems). Besides modern, field-tested instrumenta-tion and measurement technology, the group has extensiveknowledge of EMC testing and the related assessment of rail-way vehicles and infrastructure. This combination of advan-ced technology and professional expertise is much used andhighly valued both by internal customers and by externalclients throughout the railway industry.
The services listed below represent only a fraction of thegroup’s portfolio:
Measurement and evaluation of interference currents in electric and diesel-electric railway vehicles (traction units, locomotives, passenger coaches, special-purpose vehicles, etc.); near-field interference of diesel-electric vehicles with electric power supply equipment, such as the train lineInvestigation of how vehicles influence track sensors such as axle counters, wheel sensors and level crossings
Electromagnetic Compatibility
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Measurements to study how safety and signalling systems are influenced by the electric and magnetic fields experien-ced in railway operations (vehicle/infrastructure and infrastructure/infrastructure interactions)Measurement and examination of safety and signallingsystems, measurement of return currentMeasurement and assessment of electric and magnetic fields in railway operations (infrastructure/track-installa-tion, vehicles); determination of the local magnetic fielddistribution in the vicinity of traction current supply systems(accredited test procedure)Laboratory tests to examine electromagnetic interference and disturbance in signalling components
T.TVI 34(1) Jens BurandVölckerstraße 5, 80939 Münchenphone +49 89 1308-7432, fax +49 89 [email protected]
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We carry out inspections, measurements, tests, trials and full-scale studies as well as providing technical advisory services.
We also perform the following procedures on analogue anddigital radio systems:
Certification and homologation testing of railway radiocommunication com-
ponents (train radio, shunting radio, mobile phones, etc.)Radio coverage along railwaytraffic routes (accreditation process by DIN EN 17025)Measurements to achieve the optimum position of radio antennas on rail vehiclesInteroperability tests for European approval procedures (PBKA train radio module, GSM-R terminals, etc.)Functional testing of hardware and software components Determining “Quality of Service” parameters for GSM-R on ETCS and high-speed linesTesting the immunity to interference and the radio compatibility of rail vehicles by DIN EN 50121Localisation of radio disturbances
Telecommunication, Radio
Tests and Trials
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Equipment and instrumentation used includes:
Radio measuring carQuality-of-Service measuring station Radio measuring van (road vehicle)EMC absorber cabin
T.TVI 34(1) Eckehard WilhelmVölckerstraße 5, 80939 Münchenphone +49 89 1308-73 54, fax +49 89 [email protected]
Tests and Trials
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We use full-scale rigs to test the productive efficiency ofwheels, axles, rails, switch systems and other track and vehiclecomponents. Components are examined at full scale and underservice loading conditions. Focus areas are materials concepts,the improvement of maintenance routines, noise control anddiagnostics methods.
Details of the test rigs
Wheel/rail system test rig for wheelsets and rails for speedsof up to 330 km/h or track components up to 3 m longLinear test rig for roll-over tests on switch components andwelded permanent way structures at full scaleWheelset rig of variable track gauge with which to test original wheelsets for all track gauges commonly in use in Europe at speeds of up to 160 km/hServohydraulic testing machine to 250 kN
Testing assignments
To establish wear and rolling contact fatigue in various materials for wheels, rails and switch systemsRoll-over tests on rails, switch blades and common crossings To influence friction coefficients by means of lubrication and friction modifier
Wheel-Rail-Contact
Tests and Trials
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To certify permanent-way welding methods/filler materialsTo establish the remaining service life of wheelsets with artificial pre-existing damageStrength testing of components on variable-gauge wheelsets, wheelsets with rubber-sprung wheels etc.To trial diagnostics systems for wheelsetsTo record rolling noise and how it is affected by wheel noiseabsorbers and dampers (acoustic tests).
T.TVI 53 Dr.-Ing. Katrin MädlerBahntechnikerring 74, 14774 Brandenbg.-Kirchmöserphone +49 3381 812-337, fax +49 3381 [email protected]
Tests and Trials
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The “Materials Engineering, Weak-Point Analysis” departmentat DB Systemtechnik GmbH in Kirchmöser provides a wide rangeof testing and engineering services for the approval, operationand maintenance of railway vehicles and the track they run on.This also embraces services to assess the interaction betweenvehicle and track components in the integrated railway system.
The services performed involve certified routines as laid downin DIN EN ISO 9001: 2000. Our customers include both domesticGerman and international train operators, vehicle systemfirms and rail component makers plus Germany’s Federal Rail-way Authority (EBA) and Federal Railway Accident InvestigationBody (EUB). We can look back over more than 40 years ofexperience acquired in the field of materials engineering,specifically focusing on damage analysis, uses for materials,bonding techniques, surface finish techniques/corrosioncontrol up to and including fire safety for railway vehicles.
The focus areas enumerated below form but part of theoverall service we provide:
Damage analysis inspection body (for vehicles and track)Specialist consultancy on materials engineering in the vehicle/track systemMaterials testing for Manufacturer’s Product Qualification exercises (HPQ)Bonding techniques and non-metallic materialsCoating techniques, corrosion control, cleaning chemicalsFire safety and fire system tests
Material Science
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The following test rigs and technical facilities are available forthe purpose of providing the testing and engineering servicesset out above:
Wheel/rail system test rig (full-scale)Heavy-load wheel/rail test rig (full-scale)Linear wheel/rail test rig (full-scale)Servohydraulic testing machine to 250 kNPulsator to 500/1000 kN (dynamic/static)Spectrum analyserMetallography involving all the usual means of testingFractographic laboratory including stereo and scanning electron microscope with EDXMechanical materials testing inclusive of that for fracture toughnessFire test laboratory with cone calorimeter, smoke box, combustion box and fire pillar.
T.TVI 53 Dr.-Ing. Katrin MädlerBahntechnikerring 74, 14774 Brandenbg.-Kirchmöserphone +49 3381 812-337, fax +49 3381 [email protected]
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The regular monitoring and approval of measuring and testresources, machines, measuring facilities and measuring pro-cesses is a key constituent of the quality management pro-cess. Though we essentially specialise in measuring and te-sting methods for the railway, we also provide our services fora great number of other measuring variables. We have a high-performing calibration and testing body at our disposal thathas been accredited as a laboratory for the German Calibra-tion Service (DKD) and is recognised by Germany’s FederalRailway Authority (EBA).
Calibration and testing
To DIN EN ISO/IEC 17025Calibration of standardised and rail-type measuring and test resources as well as of machines and complex measuring facilitiesCalibration in our own laboratories and on siteDevelopment of in-house calibration and testing methods
Test resource monitoring for all measuring and test resources calibrated in our laboratories
Test resource administration with the QMSOFT test resource database Test resource monitoring with regular notification of customers
Suitability of test processes for quality and safety-criticalmeasuring and testing processes
Analysis of complex measuring processesSpecification of extended measuring uncertainty for measuring processesAssessment of the suitability of measuring processes for their intended purposeAdvice on the scope for enhancing measuring processes
Metrology, Calibration, Verification Processes
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Consultancy and training for test resource monitoring
Dealing with fundamental tasksAdvice/training on special-purpose and rail-type measuring and testing methods
Development and distribution of rail-type measuring and testing methods
New and further development Work on the catalogue for railway depot production resources (EWF)Procurement of railway depot production resources (EWF)
Calibration and testing methods adopted
Linear measurements with the DKD laboratory; e.g.Pressure measurements with the DKD laboratory; e.g.Force measurements with the DKD laboratory; e.g.Torsion measurements with the DKD laboratory; e.g.Electrical measurements with the DKD laboratory; e.g.Further physical variables, e.g.
T.TVI 54 Frank WolfEmilienstraße 45, 09131 Chemnitzphone +49 371 493-2021, fax +49 371 [email protected]
DB Systemtechnik
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References
Client DescriptionAlstom High speed train ETR 610
approval CH/G
Alstom Belfort Diesel electric locomotive BB475 tests, expert opinions G
Alstom DMU Coradia tests CZ/S/G
Ansalodobreda V250 approval running technology BEL/NL
Bombardier EMU Talent 2 tests, expert opinions G
Bombardier Electric locomotive Traxx approval G
CargoBeamer AG Freight waggon CargoJet approval G
DB Fernverkehr ICE1, ICE 2 approval after refurbishment G/CH
Kockums Industrier AB Freight waggon Laaeilprs und Lgss-y, approval S
Schweerbau Rail Grinding machine RG48IIapproval G
Siemens EMU Desiro MLtests, expert opinions G/BEL
DB Systemtechnik
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Client DescriptionSiemens Electric locomotive Vectron
approval G/CH/A/I
Siemens High speed train Velaro approval management, tests, G/F/BEL/RUS
Stadler DMU Flirt tests EMC G
Bombardier India Metro wagon Delhi Climatic tests
Equipment- GSM-R terminals manufacturer Certification, approval
G/F/BEL/A/CH
BLS Lötschbergtunnelmeasuring overhead line CH
ÖBB Sittenbergtunnel measuring overhead line A
DB Netz GSM-R-network function tests radio also border area D
SBB Sleepers test of infrastructure CH
Contact
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Contact
Klaus Albert Bolten, Head of the business unit, wasborn on 7 February 1949 in Wilster, in the Steinburgdistrict in the north of Germany. After completing hisschool education, he studied electrical engineering atthe Technical University of Hannover between 1967 and1973. After graduating, he joined the West Germannational railway Deutsche Bundesbahn as a traineeengineer in the Mechanical and Electrical Engineeringdivision, where he completed his Staatsexamen (aGerman professional qualification in areas subject tostate supervision). In 1976, Klaus Albert Bolten joinedthe Bundesbahn Central Office in Minden where heworked in the field of freight wagon engineering. After aperiod working at the DB Central Office, he switchedfields and from 1994 to 2005 worked as a projectmanager and later as head of the Technical Systemssubdivision for the ICE T high-speed tilting trains usedon long-distance services. Since January 2006, KlausAlbert Bolten has been head of the Conformity andCertification business unit within DB Systemtechnik.
T.TVP 1 Test CentreDr. Thomas Erpenbeckphone +49 571 393-5423, fax +49 571 [email protected]
T.TVP 2 Experts OrganisationFriedrich Eversmeierphone +49 571 393-5622, fax +49 5 71 [email protected]
T.TVP (1) Approval ManagementN.N.
Testing laboratories
T.TVI 12 Brake TechnologySebastian Heinzphone +49 571 393-5425, fax +49 571 [email protected]
T.TVI 23 Running TechnologyThomas Kolbephone +49 571 393-5426, fax +49 571 [email protected]
T.TVI 23 (4) Track TechnologyJörg Michael Reineckephone +49 571 393-5208, fax +49 571 3 [email protected]
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T.TVI 24 Fatigue StrengthMartin Grabphone +49 571 393-5580, fax +49 571 [email protected]
T.TVI 32 (3) Acoustics Nicolas Meunierphone +49 89 1308-7617, fax +49 89 [email protected]
T.TVI 32 (3) AerodynamicsMartin Eisenlauerphone +49 89 1308-7530, fax +49 89 [email protected]
T.TVI 32 (3) Air Conditioning SystemsMichael Meisterphone +49 571 393-5521, fax +49 571 [email protected]
T.TVI 33 Traction TechnologyDr. Frank Rickphone +49 89 1308-74 60, fax +49 89 [email protected]
T.TVI 34 (1) ERTMS, ETCSKlaus Schaffarczikphone +49 89 1308-7340, fax +49 89 [email protected]
T.TVI 34 (1) Electromagnetic CompatibilityJens Burandphone +49 89 1308-7432, fax +49 89 [email protected]
T.TVI 34 (1) Telecommunication, RadioEckehard Wilhelmphone +49 89 1308-73 54, fax +49 89 [email protected]
T.TVI 53 Rail-Wheel-ContactDr. Katrin Mädlerphone +49 3381 812-337, fax +49 3381 [email protected]
T.TVI 53 Material ScienceDr. Katrin Mädlerphone +49 3381 812-337, fax +49 3381 [email protected]
T.TVI 54 Metrology, Calibration, Verfication ProcessesFrank Wolfphone +49 371 493-2021, fax +49 30371 [email protected]
Prüfstelle und Sachverständigenorganisation
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Tests and Trialsfor railways worldwide:
accredited and certified
Imprint
DB Systemtechnik GmbH
Contact: Klaus Albert BoltenPionierstraße 10, D-32424 Minden
Phone 0571 393-5422Fax 0571 393-5653
Or send an e-mail to:[email protected]
The right to make changes is reservedSpecific details are subject to change
Issued on September 2012www.db-systemtechnik.de
