After successful completion of the course, students are able to develop the basic concept of a main component of a rail vehicle. This is either a car body or a bogie. In the design and dimensioning of the component the physical restrictions as well as manufacturing constraints and normative references.

Lay out and rough design of a rail vehicle or of one of its major components. Assembly drawings, and in parallel calculations and theoretical studies. Supporting documents especially of typical supplier components are placed at disposal.

For the development of the car body the design principles of the main components are introduced. The design space is provided as 3D geometry. The layout of main components of the car body shall be done within this design space. The main components shall be designed in a simplified way to fit the work effort to the courses hour quota. The design process is assessed in regular intervals during the course where enhancements and corrections are suggested.

Alternatively, the basic development of an bogie structure may be chosen at the beginning of the course. In this case basic requirements (max. axle load, operating range,…) and the basic bogie concept (type of wheelset guidance,…) are specified. Following these specifications a basic design concept is prepared. The design process is assessed in regular intervals during the course where enhancements and corrections are suggested.

The design of the car body shall be done on a 3D CAD system.  The assessment of the course is done after hand over of the 3D construction in a neutral geometry file format (STEP). Furthermore the car body and its main components shall be sketched on 2D drawings including main dimensions. A mass calculation and a cost estimation for the car body shall be delivered.

For the bogie the design is done on a 3D CAD system. The assessment of the course is done after handover of the 3D construction in a neutral geometry file format (STEP). Furthermore the bogie shall be sketched on 2D drawings including connection dimension. A basic numerical estimation of the dimensioning of main components (bogie frame, wheelset axles, axle bearing, springs (where appropriate)) shall be performed.

Mechanics, strength of materials, engine construction, basics of a 3D CAD system