Engineering software for rail vehicles in transition

by A. Bergmeier - 2024-02-14

The development of modern rail vehicles has long been one of the most complex tasks in industrial engineering. Today, trains consist of highly integrated systems in which electrical architecture, control technology, power supply and vehicle configuration are closely interlinked.

At the same time, time pressure, variant diversity and documentation requirements are constantly increasing. At InnoTrans, Aucotec is therefore showcasing software solutions that address precisely these issues. The company has been developing engineering software for more than 30 years and collaborates with numerous manufacturers in the rolling stock sector as well as with operators of rail and transport systems. The focus of its trade fair presentation is less on a single function and more on the question of how development processes for rail vehicles can be organised more efficiently. In the rail sector in particular, projects often arise with very similar technical foundations, yet which must still be configured differently. Variations in train lengths, the number of carriages or drive systems mean that variant management is increasingly becoming a key issue.

Aucotec applies modular principles to the rail sector

A key focus of the trade fair presentation is a new configuration approach for rail vehicles. Whilst many manufacturers have previously copied existing projects and then adapted them, Aucotec takes a more modular approach. Instead of complete templates, the system works with individual functional modules and options that can be automatically combined to create new variants. The idea originally stems from the automotive industry. There, platform strategies and modular vehicle concepts have been standard practice for years. In rail transport, this development has so far progressed much more slowly, although many basic technical functions are structured in a similar way. The system shown is based on so-called ‘typicals’ – that is, standardised basic circuits or recurring functional modules. These can be combined and expanded depending on the vehicle configuration. A new technical variant is thus automatically generated from a basic function. In the practical example, an additional motor output is added to a basic circuit. The software automatically generates a new configuration from this without the need to create a completely new template. This approach significantly reduces engineering effort, particularly for long train platforms with varying numbers of carriages. Functions remain fundamentally identical; only interfaces or separation points change depending on the respective vehicle configuration.

Variant management reduces engineering effort

According to the company, this approach can reduce the number of templates required by up to 70 to 80 per cent. This applies not only to the creation of new projects, but above all to the maintenance of existing engineering data. Previously, many manufacturers had to manage separate templates for almost every vehicle variant. As a result, changes or corrections often had to be updated multiple times. A modular data model significantly reduces this effort. Key advantages of the configuration concept:

• modular combination of technical functions
• significantly fewer templates in engineering
• automated generation of new variants
• application of modular principles from the automotive industry
• simultaneous work by multiple teams on the same project

There is also another aspect: consistent data models reduce the risk of subsequent changes during the course of the project. In rail vehicle construction in particular, subsequent adjustments often incur high costs because design, manufacturing and documentation are closely interlinked.

Rail vehicles are becoming increasingly complex

The rising demand for engineering software is directly linked to the growing technical complexity of modern vehicles. In addition to traditional electrical systems, digital control technologies, hybrid drives and networked diagnostic systems are increasingly being incorporated. In this context, Aucotec refers to projects in the field of alternative drive technologies. These include, amongst others, Deutsche Bahn’s ‘ECO-Train’ innovation project. Here, a vehicle is being converted from conventional diesel technology to hybrid technology. Such conversions place considerable demands on planning, documentation and technical consistency. Engineering platforms are increasingly playing a central role in this context. They link concept development, detailed engineering and manufacturing information within a single data model. This enables different teams to work on the same project in parallel. This capability is becoming increasingly important, particularly for international manufacturers. Development departments often work across multiple sites, whilst at the same time changes must be documented in a way that is immediately traceable.

Manufacturers and operators are driving digitalisation forward

The company’s customers include major rolling stock manufacturers as well as transport system operators. These include Stadler, Bombardier, Solaris and Škoda. It is evident that not only vehicle manufacturers, but increasingly operators themselves, are investing in digital engineering and documentation processes. The pressure to modernise is growing, particularly for existing vehicle fleets. Conversions, retrofits or new drive concepts can hardly be implemented efficiently without consistent data models. It is striking that many challenges are less technical in nature than organisational. In conversation at the trade fair, Aucotec describes this point as “a shift in mindset”. What is meant is the willingness of companies to fundamentally change established ways of working. In traditional industrial sectors in particular, processes often exist that have evolved over decades. The shift towards more digitalised and data-driven engineering methods therefore means not only the introduction of new software, but also a change in existing work cultures.

Digitalisation is bringing about lasting change in rail vehicle construction

The presentation at InnoTrans highlights just how significantly the rail sector is currently changing. Rail vehicles are increasingly evolving into modular, data-driven systems whose complexity would be almost impossible to manage without specialised engineering tools. At the same time, a trend is emerging that is already familiar from other industries: standardisation and product variety are no longer mutually exclusive. Instead of entirely bespoke projects, flexible modular systems are being developed that can be adapted to different requirements. For manufacturers, this means shorter development times and reduced maintenance costs. Operators benefit from more consistent data and modernisation projects that are easier to plan. It is precisely at this interface that Aucotec positions itself with its solutions for rail transport.