Railway
Structural verifications and documentation for railway vehicles and on-track machines, according to the EN product standards.
Structural verification of a bogie frame to EN 13749
Static and fatigue FEM analysis of the bogie frame with the EN 13749 load cases for the vehicle category.
Structural verification of a freight wagon underframe and body to EN 12663-2
FEM analysis of the freight wagon with the longitudinal, vertical and lifting loads of EN 12663-2.
Structural verification of a railway axlebox
Static and fatigue FEM verification of the axlebox body with loads derived from EN 13749 and the requirements of EN 12082.
Railway axle verification to EN 13103-1
Stress calculation and verification of the axle sections with the EN 13103-1 method.
Verification of the headstock and buffer and coupler attachments
FEM verification of the headstock with the longitudinal compressive and tensile loads of EN 12663.
Verification of the anchorage of on-board equipment
Verification of supports, bolts and welds of an item of equipment with the design accelerations of EN 12663-1.
Stability verification of an on-track machine to EN 14033
Stability in working and transfer mode of a track maintenance machine with cranes or booms.
Masses, centres of gravity and wheel load distribution
Calculation of mass, centre of gravity, axle and wheel loads and imbalances from the 3D model.
Gap analysis of an on-track machine's technical file
Requirement-by-requirement comparison between the existing documentation and what EN 14033 and related standards require.
Gauge clearance and reduction calculation to EN 15273-2
Check of the vehicle profile against the reference gauge, with reductions on curves and suspension movements.
Braking calculation: braked weight, stopping distances and parking brake
Braked weight, braked weight percentage, stopping distances and parking brake check for a vehicle or on-track machine.
Verification of safety against derailment on twisted track
Calculation of the Y/Q ratio on twisted track under the conditions of EN 14363, for vehicles and on-track machines.
Curve negotiation and bogie rotational freedom
Minimum horizontal and vertical curve radii, bogie rotation and interference under the body.
Traction performance of a vehicle or on-track machine
Tractive effort–speed diagram, resistances to motion and starting check on the maximum gradient.
Verification of the suspension springs of a railway vehicle
Stiffness, tare and loaded deflections, travel reserve and fatigue of the helical suspension springs.
Vehicle compatibility with axle counter systems
Documentary check of the compatibility of wheels, metal masses and electromagnetic fields with axle counters.
Compatibility with hot axlebox detectors
Check of the axlebox target zone and prohibited zone relative to trackside detectors according to EN 15437-1.
Assessment of the significance of a change (EU Reg. 402/2013)
Application of the criteria in art. 4 of the common safety method to establish whether a change is significant.
CSM-RA risk analysis for a vehicle modification
Hazard identification, acceptance criteria and hazard log according to the common safety method.
Drawing of the vehicle's markings and pictograms
Mandatory external and internal markings, positions and dimensions, for wagons, on-track machines and traction units.
Verification of the locking devices in transfer position
Strength of the mechanical locks of cranes, booms and equipment of the on-track machine during running.
Operating and maintenance manual for an on-track machine
Manual compliant with the content required by EN 14033 and the Machinery Directive, or completion of an existing manual.
Maintenance plan for a railway vehicle
Plan with tasks, intervals and acceptance criteria, structured for the entity in charge of maintenance.
Weighing plan and analysis of the results
Weighing procedure, tolerances and comparison between measured and calculated axle and wheel loads.
Ballast calculation for an on-track machine
Mass and position of the ballast to meet the required wheel loads, stability and centre of gravity.
Mechanical verification of a monobloc wheel to EN 13979-1
FEM analysis of the wheel with the load cases on straight track, in curves and over switches, and fatigue verification of the web.
Classification of welded joints to EN 15085-3
Safety class, stress class, quality and inspection class of every joint of a sub-assembly.
Definition of the vehicle reference masses to EN 15663
Design and operating masses of the vehicle in the prescribed load conditions, with the axle and wheel loads.
Compatibility of the vehicle with the line categories to EN 15528
Classification of the vehicle against the line categories by axle load and mass per metre.
Verification of steps, handles and handrails to EN 16116
Geometry and strength of steps, platforms and handles for shunting staff on freight wagons and vehicles.
Fire compliance matrix of the materials to EN 45545-2
List of the vehicle materials with the requirement, the hazard level and a check of the available test reports.
Lifting and re-railing plan to EN 16404
Lifting points, re-railing configurations and loads on the equipment for recovering a derailed vehicle.
Interoperability constituents
Technical dossiers, requirement matrices and test plans for headlamps, horns, windscreens, buffers, couplers, axleboxes and PRM lifts.
Technical dossier for head and tail lamps (EN 15153-1)
Requirements matrix, test plan and dossier for lamps as interoperability constituents.
Technical dossier for audible warning devices (EN 15153-2)
Sound level and frequency requirements, tests and dossier for horns as interoperability constituents.
Technical dossier for front windscreens (EN 15152)
Impact resistance, optical quality, spalling and visibility: requirements, tests and dossier for the windscreen.
Technical dossier for buffers (EN 15551)
Static and dynamic characteristics, absorbed energy, interface dimensions and buffer tests.
Technical dossier for draw gear and screw coupling (EN 15566)
Strength, interfaces and tests of couplers, tensioners and draw gear.
Technical dossier for a PRM access lift (EN 16586-2)
TSI PRM requirements, kinematic analysis, rated load, speeds and accelerations, test plan for the on-board lift.
Technical dossier for axleboxes (EN 12082)
Performance requirements, rig tests and documentation of axleboxes as interoperability constituents.
Test specification for an accredited laboratory
Test document for a component: configuration, instruments, measurement points, acceptance criteria and standards references.
Machine design
Complete mechanical design of one-off machines and special assemblies, from the concept to the shop drawings and the bill of materials.
Design of an unwinding or rewinding unit for web materials
Complete mechanical design of an unwinder or rewinder for reels, from the concept to the manufacturing drawings and the bill of materials.
Design of a manipulator for heavy or bulky parts
Gantry or manipulator on linear axes with a dedicated gripper, to move parts that a standard gripper cannot hold.
Design of a machine for processing vegetable products
Compact machines for sorting, size reduction, drying or dosing of bulk products, in a design suitable for food contact.
Design of a workbench with a vacuum clamping table
Perforated table with a zoned vacuum circuit, supporting structure and flatness check under load.
Design of a biomass heat generator
Pellet or wood chip boiler with hopper, feeding screw and exchanger, from the concept to the manufacturing drawings.
Mechanical components
Standards-based verifications of shafts, joints, welds, bearings, gears and machine elements.
Static and fatigue check of a shaft
Verification of up to 5 critical sections with loads, support reactions, notches and safety factors.
Verification of a bolted joint to VDI 2230
Preload, tightening torque, external load, bolt fatigue and head bearing pressure for a joint.
Static and fatigue verification of welded joints
Verification of up to 5 welds with the nominal stress method and detail categories.
Selection and verification of a shaft's bearings
ISO 281 life with aISO, static safety and catalogue selection for the two supports of a shaft.
Verification of a gear pair to ISO 6336
Geometry, tooth bending and surface pressure (pitting) check of a spur gear pair.
Verification of keys and splines
Flank pressure and shear for shaft-hub connections with a key or splines.
Calculation of a helical spring to EN 13906
Sizing or verification of a compression, extension or torsion spring, including fatigue and buckling.
Verification of pins and joints
Shear, bending and contact pressure check of pins, forks and eyes.
Verification of an interference fit
Interference, contact pressure, transmissible torque and assembly temperature of a shrink fit.
Calculation of disc springs to EN 16983 and EN 16984
Load–deflection curve of a stack of disc springs, stresses and fatigue verification.
Sizing of O-ring grooves to ISO 3601
Selection of the O-ring and groove dimensions for static and dynamic, radial or axial seals.
Balance quality grade and permissible residual unbalance to ISO 21940-11
Quality grade G, permissible residual unbalance and distribution over the correction planes of a rigid rotor.
Verification of a bevel gear pair to ISO 10300
Load capacity against pitting and tooth breakage of a straight or spiral bevel gear pair.
FEM analysis
Finite element analysis of a component with a defined scope: static, fatigue, modal, buckling.
Static FEM analysis of a component
Linear analysis of a single component with up to 3 load cases, convergence and results check.
Fatigue FEM analysis of a component
Fatigue verification with a defined load spectrum, S-N curves and correction factors.
Modal analysis: natural frequencies and mode shapes
Natural frequencies of a component or structure and comparison with service excitations.
Buckling verification
Critical load of slender struts, columns and panels with the standard's method or buckling analysis.
Non-linear FEM analysis with contacts
Simple assembly of up to 5 parts with contacts, friction or material plasticity.
Steady-state thermal analysis of a component
Temperature distribution and heat flows with convection and radiation, and any thermal stresses.
Lifting
Lifting and gripping equipment to EN 13155, overhead cranes, jib cranes, lift tables and load securing on vehicles.
Verification of a lifting beam to EN 13155
Structural verification of the lifting beam, attachments and gripping points with the factors of EN 13155.
Verification of eye bolts and welded lifting points
Verification of lifting plates, welded or bolted eye bolts and the attachment structure for the stated capacity.
Verification of a lifting frame
FEM analysis of a frame or spreader with several gripping points using the EN 13155 combinations.
Verification of a gripper or gripping device
Clamping force, friction coefficient and strength of mechanical lifting clamps.
Verification of the girder of a single-girder overhead crane to EN 13001 and EN 15011
Static and fatigue verification of the main girder and of the end carriages of a single-girder overhead crane.
Verification of a jib crane to EN 14985
Verification of the jib, column, slewing and base plate of a pillar or wall-mounted jib crane.
Verification of a lift table to EN 1570-1
Structural verification of the scissor linkage, platform and base and stability of a scissor lift table.
Load securing plan on a road vehicle to EN 12195-1
Number and type of lashings or anchorages to transport a defined load safely.
Structures and steelwork
Base frames, machine frames and racking in steel and aluminium to the Eurocodes and the product standards.
Verification of a steel machine base or frame
Strength, stability and deformation check of a frame in sections with the machine's loads.
Static verification of pallet racking to EN 15512
Calculation report for uprights, beams and bracing, with the load notices for each bay type.
Verification of an aluminium machine structure to EN 1999-1-1
Verification of aluminium frames and profiles with the strength reductions in the welded zone.
Welding and fabrication
Welding procedure specifications, execution classes and quality requirements for workshops that weld.
Drafting of a welding procedure specification (WPS) to EN ISO 15609-1
Preliminary WPS for a defined joint: process, materials, preparation, parameters and sequence.
EN 1090-2 execution class for machine frames and steelwork
Choice of the EXC execution class and specification of the manufacturing requirements for a machine frame or machine steelwork.
Gap analysis of the quality requirements for welding to EN ISO 3834-2
Comparison between the organisation of the workshop and the requirements of EN ISO 3834-2, with an action plan.
Machine safety
Calculations and checks required by the harmonised standards: safety distances, performance level, access, ergonomics, hygiene and ATEX.
Calculation of the safety distances of a danger zone
Minimum distances of barriers, guards and controls according to EN ISO 13855 and EN ISO 13857.
Calculation of the performance level PL to EN ISO 13849-1
Achieved PL of up to 3 safety functions with defined components, compared with the PLr.
Risk assessment of a simple machine (EN ISO 12100)
Complete risk assessment for a machine with up to 3 danger zones, with reduction measures and residual risk.
Instruction manual for a machine
Operating and maintenance manual with the content prescribed by the Machinery Directive and the structure of EN ISO 20607.
Verification of guards and interlocks
Requirements for fixed and movable guards and choice of interlocking devices according to EN ISO 14120 and EN ISO 14119.
Documentation for partly completed machinery
Relevant technical documentation, assembly instructions and declaration of incorporation.
Verification of walkways, stairs and guard-rails of a machine to EN ISO 14122
Geometry and strength of platforms, stairs and guard-rails giving access to the machine.
ATEX ignition hazard assessment for non-electrical equipment
Analysis of the ignition sources of mechanical equipment intended for areas with explosive atmospheres.
Ergonomic assessment of a machine workstation
Manual handling, forces and postures of the workstation to the ergonomic standards of the EN 1005 series.
Verification of the hygiene requirements of a food machine to EN 1672-2
Hygiene zones, materials, surfaces and cleanability of a machine for the food industry.
Fluids and energy
Hydraulic circuits, pressure vessels and piping, safety valves, flow measurement and lighting calculations.
Sizing of a hydraulic circuit
Cylinders, pump, motor, piping and pressure losses of a circuit with up to 3 actuators.
Pressure losses and pump selection
System curve, operating point and pump selection for a water or process fluid circuit.
Lighting calculation of a workplace
Point-by-point calculation with real photometric data: illuminance, uniformity and UGR according to EN 12464-1.
Verification of a gasketed flange joint to EN 1591-1
Bolt tightening torque, tightness and strength of a flange joint in the test and operating conditions.
Sizing of a safety valve to EN ISO 4126
Flow to be discharged, orifice area and selection of the safety valve for gases, vapours or liquids.
Calculation of a simple pressure vessel to EN 13445-3
Thicknesses of shell and heads, openings and reinforcements, flanges and saddles of a cylindrical vessel, with the design-by-formula method.
Verification of a piping line to EN 13480-3
Thicknesses, bends and branches, thermal flexibility and support loads of a line up to 30 metres.
Sizing of an orifice plate flow meter to EN ISO 5167-2
Bore diameter, differential pressure and uncertainty of a calibrated orifice plate.
Sizing of a vacuum clamping table
Holding force, leakage flow, pump selection and deflection check of a perforated table.
Assessment of a biomass heat generator to EN 303-5
Heat balance, heat exchanger, draught and safety requirements of a pellet or wood chip boiler up to 500 kW.
Thermal calculation of a radiant panel to EN 1264
Thermal output, circuit spacing, pressure drops and surface temperature of a water radiant panel.
Transmissions and drives
Selection and verification of gearmotors, belts, ball screws and linear guides.
Sizing and selection of a gearmotor
Torque, power, inertia and service factor: catalogue selection of motor and gearbox for an application.
Sizing of a belt drive
Profile, number of belts, pulleys, centre distance and shaft load for a V-belt or toothed belt drive.
Verification of a ball screw
ISO 3408-5 life, buckling load, critical speed and drive torque of a screw axis.
Selection and verification of linear guides
Carriage loads, ISO 14728-1 life and static safety for a linear axis.
Sizing of a belt conveyor
Belt tensions, motor power, pulleys and take-up of a belt conveyor.
Sizing of a powered roller conveyor
Roller loads, chain or belt drive, power and accumulation for a roller conveyor.
Sizing of a chain drive to ISO 606
Selection of the roller chain, number of teeth, centre distance and lubrication of a chain drive.
Sizing of a coil unwinding unit
Reel shaft, brake or drive motor, idler rollers and supporting frame of a cantilever or centre-mounted unwinder.
Sizing of a Cartesian manipulator on linear axes
Cycles, loads, choice of the electromechanical axes and deflection check of a two- or three-axis gantry.
Sizing of a conveying or dosing screw
Diameter, pitch, speed, power and shaft check of a screw conveyor with its loading hopper.
Drawings and documentation
Manufacturing drawings, 3D reconstructions and tolerance stack-ups.
Detail drawing of a part from the 3D model
Dimensioned manufacturing drawing with dimensional and geometric tolerances, roughness and notes, for a part.
3D reconstruction of a part from a 2D drawing
Parametric 3D model of a part from a 2D drawing or a dimensioned survey.
Tolerance stack-up analysis
Chain of up to 10 links with worst-case and statistical (RSS) methods, and proposed tolerances.
Bill of materials and part numbering of an assembly
Multi-level structured BOM of up to 50 part numbers, with numbering, materials and commercial components.
Assembly drawing with exploded view and bill of materials
Assembly drawing with views, numbered exploded view and component table.
Functional GPS dimensioning of a part
Datum system, geometrical and dimensional tolerances of a part to the GPS standards.
Safety signage plan for a machine
Selection and position of the safety signs and labels, with print-ready files.
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