Advanced Car body shells for railways and light material and innovative doors and train modularity - S2R-OC-IP1-01-2019

Deadline: Jun 18, 2019  
CALL EXPIRED

SPECIFIC CHALLENGE

Specific challenges for the different topics are:

Car Body Shell

Cost is one of the key factors impeding entry to the market for composite technologies. An investigation on new technologies able to address this challenge is needed, e.g. 3D additive technologies that allows quick and cheap tool manufacturing to successfully introduce the composite in the Rail Industry, especially for large dimensions tools. 3D printer technology is considered very promising, although any other technology covering the same requirements could also be considered. The potential benefits that structural health monitoring systems could offer are the cost reductions regarding maintenance and operation, Reduction of inspection time, early damage detection to enhance safety and allow for less drastic and less costly repairs.

Doors

Also for doors, cost is one of the key factors impeding entry into the market for composite technologies. Special emphasis is needed on cost reduction technologies to make the composite technologies affordable for Rail industry. For that purpose, a specific focus on manufacturing tools is necessary.

Due to the characteristics of door leaves which shall have low thickness (mainly between 32 mm till 50 mm), low weight, relatively low tightness, they are on the weak point to allow important comfort in the vestibule or in the vicinity of the door. As a consequence, other solutions than strictly door solutions should be studied in order to improve passenger comfort and allow phone conversation in the door vicinity.

Solutions have to be provided for the accessibility of trains to all users. A significant challenge is to improve train services and create a real universal service, allowing independent and easy access to all passenger categories, including passengers with reduced mobility.

Interiors

The challenge is to propose new low cost, modular and aesthetic interiors designs (passengers room) matching the concepts of new fixation systems developed during the S2R-CFM-IP1-01-2019 call.

A further challenge is to be able to decide which interiors and cabin layout use before building a mock- up demonstrating the modularities allowed by the new concept of plug&play fixation systems.

Cost is one of the key factor preventing the entry into the market of composite technologies. For that purpose, a specific focus on manufacturing tools is necessary.

Following the results of PIVOT (S2R-CFM-IP1-01-2017) work around innovative driver cabin and new HMI are one of the challenges to address. Gesture, sound and voice control are the new technologies to master in the cabin of the future. For this, human factors, cognition and cultural differences impacts have to be taken into account to design the most efficient cabin commands.

One of the most interesting could be the integration of the low volt circuit as a way to reduce assembly time and the associated cost. Currently, an industrial application with this functionality does not exist.

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SCOPE

Proposals addressing S2R-OC-IP1-01-2019 is part of the Car body shells, innovation doors and train modularity developments and activities within the Shift2Rail (S2R) programme (respectively TD1.3, TD1.6 and TD1.7) and is complementary to the S2R-CFM-IP1-01-2019. These activities are described in the S2R Multi-Annual Action Plan (MAAP) – TD1.3, TD1.6, TD1.7 and the S2R-CFM-IP1-01-2019 topic description. The detailed information about the scope of the Open Call (OC) contribution is mentioned

in the

1. 2.

3. 4.

5. 6. 7. 8. 9. 10. 11.

following work streams.

New tooling for composite car body manufacturing
Car body Structural Health Monitoring Systems for Composites and for Metal-Composite Interfaces
Process automation concepts for Composite Car body Manufacturing
Process integrating joint concepts and modular concepts for Composite Car body Manufacturing
New tooling for Composite Door Leaves manufacturing
Solutions for thermal and noise reduction in the neighbourhood of the door
Accessibility to passenger trains (ramps, thresholds, gap filler)
Modular Interior’s concepts and virtual immersive interior design configurator tool
New tooling for Composite interiors manufacturing
Innovative Driving cabin: European survey to define new human-machine interactions Integrated low voltage circuits in a wall/roof/floor panel .

Proposals should address all work-streams described below, in line with the Shift2Rail Multi-Annual Action Plan (MAAP) – TD1.3, TD1.6, TD1.7:

Car Body Shell

Worstream 1 : New tooling for composite car body manufacturing

Proposals should provide the necessary tools in the selected technology in order to manufacture the car body prototype defined in PIVOT (S2R-CFM-IP1-01-2017) project31. To test the technology adequately, the partners should be ready to develop the tool ́s technologies specifically for the selected different manufacturing processes defined during PIVOT (S2R-CFM-IP1-01-2017) project32. The test of the technology should provide relevant parameters in order to evaluate costs, vacuum integrity, surface roughness, manufacturing time, in different sizes and complexity. Large size panels, roof panels, beam parts and frame parts tools including complex geometries should be considered. The size of the tools should allow production of standard carbody parts and should be focused on High Speed and Urban carbodies defined during PIVOT (S2R-CFM-IP1-01-2017) project.33 Activites are expected to reach TRL5/6.

Workstream 2 : Car body Structural Health Monitoring Systems for Composites and for Metal- Composite Interfaces

31 Relevant information can be found on the PIVOT website (http://projects.shift2rail.org/s2r_ip1_n.aspx?p=pivot) in particular with the published document “PIVOT project factsheet” (direct link: http://projects.shift2rail.org/download.aspx?id=e1d80a5c-a383-4820-8d85-ecb55ac71bd9 )
32 Relevant information can be found on the PIVOT website (http://projects.shift2rail.org/s2r_ip1_n.aspx?p=pivot) in particular with the published document “PIVOT project factsheet” (direct link: http://projects.shift2rail.org/download.aspx?id=e1d80a5c-a383-4820-8d85-ecb55ac71bd9 )

33 Relevant information can be found on the PIVOT website (http://projects.shift2rail.org/s2r_ip1_n.aspx?p=pivot) in particular with the published document “PIVOT project factsheet” (direct link: http://projects.shift2rail.org/download.aspx?id=e1d80a5c-a383-4820-8d85-ecb55ac71bd9 )

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Identification and implementation in the Car body demonstrator specified in PIVOT34 that will be produced by S2R-CFM-IP1-01-2019 of the most suitable technologies of structural health monitoring systems for railway carbodies. The proposals should apply health monitoring in different components (e.g. main frame, lateral panel, roof). Locations and types of potential failure (both globally and locally) should be defined. Activites are expected to reach TRL5/6.

Workstream 3 : Process automation concepts for Composite Car body Manufacturing

Proposals should address process automation technologies in manufacturing of composite components for the rail industry. The proposed technologies should reduce the cost and the time needed to manufacture the composite structures in the different process steps involved. The proposal should investigate flexible automated concepts with limited investments costs.

The following processes should be considered:

o Process automation concepts based on competitive OOA (Out of Autoclave) processes with special interest on liquid moulding processes and OOA low temperature curing pre-preg. These process automated solutions should address the main process steps and especially fibre/ fabrics cutting (and stacking- kitting if needed), laying over different geometries (either complex double curvature or simple longitudinal profiles), 3D preforming, resin impregnation and curing.

o Process automation concepts based on low cost composite materials like dry fibre reinforcements in various formats, e.g. NCF (Non Crimp Fibre) materials.

o Process automation concepts with potential to be applied to the car body structures including mainly big size structures (main car body structure including big panels and beams) both monolithic and sandwich, also some smaller and more repetitive parts (like ribs or similar) and some specific parts like doors.

o Process automation concepts providing reduced amount of material scrap. Activites are expected to reach TRL5/6.

Workstream 4 : Process integrating joint concepts and modular concepts for Composite Car body Manufacturing

The Proposal should provide tooling which integrates the joint before curing process in the preforming phase (joining of preforms, inserts integration in the preforms, etc.). The parts to be integrated are coming from Car body integration concept defined in Pivot (add footnote). 2 areas should be considered:

o New methods to integrate the joints concepts in the current manufacturing processes. The proposal should deliver a physical demonstrator compatible with the Car body demonstrator specified in PIVOT35 that will be produced by S2R-CFM-IP1-01- 2019 validating the new methods.

o Propose new technologies as for example 3D additive technologies, allowing quick and cheap tool manufacturing. The proposed technology should reduce the cost and

34

Relevant information can be found on the PIVOT website (http://projects.shift2rail.org/s2r_ip1_n.aspx?p=pivot) in particular with the published document “PIVOT project factsheet” (direct link: http://projects.shift2rail.org/download.aspx?id=e1d80a5c-a383-4820-8d85-ecb55ac71bd9 )
35 Relevant information can be found on the PIVOT website (http://projects.shift2rail.org/s2r_ip1_n.aspx?p=pivot) in particular with the published document “PIVOT project factsheet” (direct link: http://projects.shift2rail.org/download.aspx?id=e1d80a5c-a383-4820-8d85-ecb55ac71bd9 )

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the time needed to manufacture the tools. The technology should contemplate the easy modification of the tools in order to permit the re-use of the tools from one project to another as a way to reduce the non-recurring cost. 3D printer technology is considered very promising, although any other technology covering the same requirements could be also considered. The proposal should deliver a physical demonstrator compatible with the Car body demonstrator specified in PIVOT36 that will be produced by S2R-CFM-IP1-01-2019 validating the new identified technologies.

Activites are expected to reach TRL5/6.

Doors
Workstream 5 : New tooling for Composite Door Leaves manufacturing

Proposals should provide the necessary manufacturing tools in thetechnology selected in PIVOT37 to S2R-CFM-IP1-01-2019 project in order to manufacture the door prototype defined during PIVOT project38. The aim will be to test the technology in order to evaluate it in terms of cost, vacuum integrity, surface roughness, manufacturing time, etc. Proposals should consider a regional train as a target. The activity is expected to reach a TRL5-6.

Workstream 6 : Solutions for thermal and noise reduction in the neighbourhood of the door

Proposals should develop active solutions to reduce the noise in the vestibule in the vicinity of the doors, with the target to allow easy phone conversation and improved acoustic comfort. In addition, recommendations and development of passive solutions that could increase noise absorption are expected. Proposals should apply solutions to reduce the feeling of "hot" and "cold" surfaces.

The developed solutions will be tested within S2R-CFM-IP1-01-2019 project. A regional train should be considered for the further integration of the developed solutions. The activity is expected to reach a TRL5-6.

Workstream 7 : Accessibility to passenger trains (ramps, thresholds, gap filler)

Proposals should evaluate the demonstrator and solutions developed within S2R-CFM-IP1-01-2019 action selected for funding with a representative panel of persons with reduced mobilities. Potential updates of the specifications to S2R-CFM-IP1-0 1-2019 project in order to manufacture the interiors mock-up defined during PIVOT (S2R-CFM-IP1-01-2017) project39 and the necessary development test. The testing of the technology should be performed in order to evaluate it in terms of cost and feasibility. This technology will be used to manufacture the interiors mock up in the action timeframe. Special care it should be taken to solve technical and fundamentals aspects such as as curing conditions, drape ability, repair technologies, joint technologies, and plug & play technologies to connect the panel in between and the equipment. The technology should support the easy

36 Relevant information can be found on the PIVOT website (http://projects.shift2rail.org/s2r_ip1_n.aspx?p=pivot) in particular with the published document “PIVOT project factsheet” (direct link: http://projects.shift2rail.org/download.aspx?id=e1d80a5c-a383-4820-8d85-ecb55ac71bd9 )
37 Relevant information can be found on the PIVOT website (http://projects.shift2rail.org/s2r_ip1_n.aspx?p=pivot) in particular with the published document “PIVOT project factsheet” (direct link: http://projects.shift2rail.org/download.aspx?id=e1d80a5c-a383-4820-8d85-ecb55ac71bd9 )

38 Relevant information can be found on the PIVOT website (http://projects.shift2rail.org/s2r_ip1_n.aspx?p=pivot) in particular with the published document “PIVOT project factsheet” (direct link: http://projects.shift2rail.org/download.aspx?id=e1d80a5c-a383-4820-8d85-ecb55ac71bd9 )
39 Relevant information can be found on the PIVOT website (http://projects.shift2rail.org/s2r_ip1_n.aspx?p=pivot) in particular with the published document “PIVOT project factsheet” (direct link: http://projects.shift2rail.org/download.aspx?id=e1d80a5c-a383-4820-8d85-ecb55ac71bd9 )

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modification of the tools in order to allow the re-use of the tools from one project to another as a way to reduce the non-recurring cost. 3D printer technology is considered very promising, although other technologies covering the same requirements could also be considered. These activities are expected to reach a TRL 5-6.

Interiors

Workstream 8 : Modular Interior’s concepts and virtual immersive interior design configurator tool

Proposals should develop several modules for ambiances, lighting and accessories (e.g. electric sockets) to demonstrate the attractiveness and the modularity of the proposed design. The activities should include the development of new interiors design adapted with the concept of quick fixation system developed in PIVOT40. The studies have to include competitive cost validated by an economic study.

Proposals should perform design studies and deliver physical mock-ups scale 1 for integration in the functional mock up developed in the complementary action S2R-CFM-IP1-01-2019. An associated virtual mock-up compatible with the configurator tool should be provided.

Proposals should develop a configurator tool using new immersive technologies to enhance several layouts (INTERIORS and driver’s CABIN) in a virtual passenger/cabin room. The purpose of the tool is to help decision before building a mock-up to finalise the studies and the potential of a full plug&play interiors. A high quality of visual appearance is expected in term of design. Fluidity and user friendly design is expected in term of use. The specifications and/or design brief are indicatively supposed to be provided by the complementary topic S2R-CFM-IP1-01-2019 at M4.

These activities are expected to reach a TRL 5-6.

Workstream 9 : New tooling for Composite interiors manufacturing

Proposals should provide the necessary manufacturing tools technology selected in PIVOT41 to S2R- CFM-IP1-0 1-2019 project in order to manufacture the interiors mock-up defined during PIVOT (S2R- CFM-IP1-01-2017) project42 and the necessary development test. The testing of the technology should be performed in order to evaluate it in terms of cost and feasibility. This technology will be used to manufacture the interiors mock up in the action timeframe. Special care it should be taken to solve technical and fundamentals aspects such as curing conditions, drape ability, repair technologies, joint technologies, and plug & play technologies to connect the panel in between and the equipment. The technology should support the easy modification of the tools in order to allow the re-use of the tools from one project to another as a way to reduce the non-recurring cost. 3D printer technology is considered very promising, although other technologies covering the same requirements could also be considered. These activities are expected to reach a TRL 5-6.

Workstream 10 : Innovative Driving cabin: European survey to define new human-machine interactions

40 Relevant information can be found on the PIVOT website (http://projects.shift2rail.org/s2r_ip1_n.aspx?p=pivot) in particular with the published document “PIVOT project factsheet” (direct link: http://projects.shift2rail.org/download.aspx?id=e1d80a5c-a383-4820-8d85-ecb55ac71bd9 )
41 Relevant information can be found on the PIVOT website (http://projects.shift2rail.org/s2r_ip1_n.aspx?p=pivot) in particular with the published document “PIVOT project factsheet” (direct link: http://projects.shift2rail.org/download.aspx?id=e1d80a5c-a383-4820-8d85-ecb55ac71bd9 )

42 Relevant information can be found on the PIVOT website (http://projects.shift2rail.org/s2r_ip1_n.aspx?p=pivot) in particular with the published document “PIVOT project factsheet” (direct link: http://projects.shift2rail.org/download.aspx?id=e1d80a5c-a383-4820-8d85-ecb55ac71bd9 )

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The aim of this topic will be to realise a European survey to define a common new HMI using gesture, sound, voice, etc. Drivers and non-driver member of staff (e.g. controllers in control room) from European operators (from minimum 3 Countries) must be included in the analysis to enlarge the panel. Return on experience in different industries (aeronautics, car, etc.) must be take into account. This topic will receive specifications from the complementary topic S2R-CFM-IP1-01-2019 indicatively at M4.

Proposal should deliver a bank of sounds and gestures to build the test and propose the first analysis of the survey.

Work stream 11 : Integrated low voltage circuits in a wall/roof/floor panel

Porposals should work on new technologies to integrate new functionalities in the composite parts, especially low volt circuits, to provide electricity to the passenger lights or to the speakers or other functionalities.

•   The circuit should be presented as a ply to be mould during the lay-up process.

•   The ply should be compatible to the current resin families (epoxy, phenolic, etc.).

•   The system should provide the adequate plug systems to connect the circuit to the equipment

•   The technology should consider repair aspects in order to restart the functionality during the

  manufacturing process or in service.

•   The technology should consider aspects of heating to avoid the risk of fires in the cabin.

  The activity is expected to reach a TRL5-6.
  An indicative scheduling of the deliverables is suggested below43:

  •   Deliverables under work stream 6 are expected by month 12

  •   Deliverables under work stream 1, 2, 4, 5 and 9 are expected by month 16

  •   Deliverables under work stream 10 are expected by month 18

  •   Deliverables under work stream 7 are expected by month 22

  •   Deliverables under work stream 3, 8 and 11 are expected by month 24

    COMPLEMENTARITY

    As specified in section 2.3.1 of AWP 2019, in order to facilitate the contribution to the achievement of S2R objectives, the options regarding 'complementary grants' of the S2R Model Grant Agreement and the provisions therein, including with regard to additional access rights to background and results for the purposes of the complementary grant(s), will be enabled in the corresponding S2R Grant Agreements.

    The action that is expected to be funded under this topic will be complementary to the actions that are expected to be funded under the following topics:

     S2R-CFM-IP1-01-2019: Development of new technological concepts towards the next generation of rolling stock, applied to major subsystems such as Car body, Running Gear, Brakes, Doors, Modular interiors and HVAC.

    The action stemming from this topic will also be complementary to actions carried out within the following projects:

     PIVOT (GA 777629). EXPECTED IMPACT

    43 The scheduling of the deliverables is provided to facilitate the complementarity with the CFM actions and it is not binding. Additionally, each deliverable may have some flexibility in the scheduling

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Car Body Shell

Development of new skills in the Railway Industry: These technologies will have an impact on the way railway vehicles are produced and maintained, keeping the value added by the conventional metal constructions and adding the new value coming from industries that are already producing systems for the aerospace and automotive industry.

Workstream 1: Improvements in manufacturing technologies: the replacement of some composite parts within the car body could be quicker and less costly than welded metallic parts (repairing of certain metallic structures can be complex). Depending on the chosen raw materials, processes used for forming composites can compete with those use for metals.

Positive side-effects for suppliers and research institutes: The need for physical characterization of composite material systems, together with the knowledge gained from the application of modern manufacturing processes, will bring activity for industries and research centres specialized in composite materials that are already working for other sectors, now gaining experience in composite railway structural applications.

Workstream 2: Integrating functions in the parts made of new materials: Train functions, such as, e.g. thermal isolation, can be integrated in a carbodies made of several materials - mainly composites, thus saving space and weight. Additionally, integrating functions such as air conduction, piping, etc., can make the whole car body system less prone to corrective maintenance. In this case, monitoring physical properties directly in the car bodies will help to gain knowledge about the behavior of the design throughout the life cycle of the structure and will make redesigns possible or even eliminate the monitoring system in the future.

Workstream 3: Improvements in composite manufacturing technologies of the composite car body to provide competitive manufacturing routes both in terms of process cost and capacity. Especially in terms of big composite structures, the process automation solutions to be developed to meet the lower cost railway industry requirements, could be applicable in the future to other sectors like aeronautics, public road transportation, wind mill sector, etc. In terms of smaller and more repetitive composite components, the process automation solutions to be developed to meet the lower cost railway industry requirements, could be applicable in the future also to other sectors like automotive, aeronautics, public road transportation, etc.

Workstream 4: Improvements in composite manufacturing technologies of the composite carboy to provide competitive manufacturing routes, reducing the need for additional joints after the manufacturing of the cured component. Integrating joint solutions to be developed to meet the railway industry requirements could be applicable in the future to other sectors like aeronautics, public road transportation, automotive, wind mill sector, etc... Process integrated joints concepts will help providing modular concepts which will be of interest especially for large structures from many sectors that can be divided in modules for easier transportation and/ or faster and more competitive production of the modules.

Doors
Workstreams 5 To 7: Once the technologies developed are fully implemented and deployed at

Shift2Rail level, the actions will contribute to the four top levels Shift2Rail KPI.

Specific metrics and methods to measure and achieve impacts should be included in the proposals, with the objective to achieve by the end of the S2R Programme the quantitative and qualitative targets defined in the S2R MAAP related to TD innovative doors in line with the relative Planning and Budget.

Interiors

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Workstreams 8 to 11: A reduction of the LCC and increase in attractiveness will be achieved with the new interior concepts. Testing of a new real-scale layout without the need to be inside a train will reduce time to market and therefore reduce LCC costs.

Knowledge in multimodal interactions taking into account cognition will contribute to design future cabin commands with high levels of operational efficiency and safety. For this task, expertise in cognitics (cognition and automation), human factors in complex systems and psychoacoustic is required.

Type of Action: Research and Innovation Action (RIA)