SIEMENS Integrated Services - Presentation ... - Siemens Mobility

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Integrated Services 

Workshop Services 

Erlangen, 2009 

Industry Sector, Mobility Division 

I MO RS IS 

Copyright © Siemens AG 2009. All rights reserved. 

Sector Industry – Mobility Division

We have the power of high-skilled personnel 

providing solutions worldwide 

Our worldwide expertise 

� Project management 

� Expert‘s report 

� Consulting 

� Engineering 

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Skill Portfolio 

� Mechanical and electrical installation 

� Welding (engineers, experts, PT-examiner) 

� Commissioning 

I MO RS IS 



Independent of the kind of material – the workshops 

fulfill all quality requirements according to ISO 9001 

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Certificates 

qualification tests of 

welders 

ISO 9606 - 2 ISO 3834 - 2 ISO 14731 ISO 15614 P.1+2 

Materials Aluminum Stainless steel Steel 

I MO RS IS 

ISO 9001 – Quality Management System 

compliant with DIN 6700, now DIN EN 15085 - Welding of rail vehicles and components 

Content 

Standards 

Procedures 

quality requirements 

of welding works 

welding coordination welding procedures 

MIG - metal inert gas MAG - metal active gas 

WIG - wolfram inert gas Electron beam welding 



Workshop Services is active around the world in 

Crash & Accident Repairs and Modernization 

Workshop Services: In our own facilities, customer’s or partnered workshops 

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� Complete solution from one hand 

� Repair of damaged vehicles in a Siemens or customer owned facility 

� As consultant or as performer 

� Front, side crash or fire damage – all accidents 

� Trams, metros or trains – all vehicles 

� Support to enhance the operational lifetime 

� Restoration of historical cars 

� Modifications as a complete solution 

� Individual support like supervision, engineering or commissioning 

� Qualified staff for overhauls 

I MO RS IS 

Crash & Accident Repair 

Modernization 



Siemens offers complete services for crash and 

accident repair including insurance processing 

Standard processes for crash and accident repair 

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Crash and Accident Repair 

Content 

� Expertise on site 

� Transport of vehicle or repair at customer facilities 

� Technical and financial damage assessment 

� Set-up of repair schedule 

� Engineering of mechanical/ electrical equipment 

� Execution of repair (disassembling, cut-off grinding, welding, 

truing, measurement, paintwork, assembly) 

� Commissioning and acceptance tests 

� Complete repair documentation 

� Loss adjustor/ insurance processing 

Benefits 

� 8 years experiences on different types of damages 

� Direct access to the complete original drawings 

� Mechanical and electrical engineering support from Siemens 

� Full service package including all paperwork 

� Repair on site is a choice of customer 

� Short repair times 

I MO RS IS 

Cut-off grinding 

Calculation 

Levelling rack 

Welding 

Documentation 

Measuring device 



No matter which crash or accident happened – 

We are able to handle it 

Overview on crash & accident repair services 

Desiro DMU Rumänien Combino Amsterdam Combino Melbourne 

Combino Amsterdam 

� Frontschaden 

Commuter 

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� Seitenschaden 

Light Rail Vehicle 

I MO RS IS 

� Frontschaden 


� Feuerschaden 




Crash repair of a front-damaged Desiro after a 

heavy crash with a cement truck 

Crash repair at customers’ site 

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Heavy front crash – Desiro DMU Romania 

Happened: 

� October 2007 in Romania 

Damages: 

� Complete front section 

� Front underframe 

� GRP-Front mask 

� Clutch 

Challenge: 

� Repair on customer’s site 

� Complex welding tasks 

Activities: 

� Shipping of welding equipment and material 

� Manufacturing of new front and under frame 

� Welding on customer’s site 

Duration of repair services: 

� May 2008 until August 2008 

I MO RS IS 



Crash repair of a front-damaged Desiro after a 

heavy crash with a cement truck 

Crash repair at customers’ site 

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I MO RS IS 



Crash repair of a side-damage Combino after 

derailment and collision with a catenary pole 

Crash repair at Siemens facility 

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Derailment & collision – Combino Amsterdam 

Happened: 

� December 2007 in Amsterdam, Netherlands 

Damages: 

� Heavy impact of sidewall and underframe 

Challenge: 

� Local repair of sidewall 

� No stripping down of car body 

� Complete repair at a Siemens workshop 

� New FEM-Calculation for repair section 

� Fastest possible repair time was requested 

Activities: 

� Using special welding procedures for repair section 

� Using special welding jigs 


� March 2008 until June 2008 

I MO RS IS 



Crash repair of a side-damage Combino after 

derailment and collision with a catenary pole 


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I MO RS IS 



Crash repair of front-damaged Combino after 

collision of two light rail vehicles 


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Frontal collision – Combino Melbourne 

Happened: 

� 24.09.2007 in Melbourne, Australia 

Damages: 

� Complete front section 

� Front underframe 

� GRP-Front mask 

� Clutch 

Challenge: 

� Shipping of the vehicle to Germany 

� Complete repair at a Siemens workshop 

Activities: 

� Procurement of main components 

� Transport to Germany 

� Construction and manufacturing of new aluminum under 

frame 

� Using special welding tools and jigs 


� April 2008 unitl September 2008 

I MO RS IS 



Crash repair of front-damaged Combino after 

collision of two light rail vehicles 


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I MO RS IS 



Accident repair after a fire-damaged Combino 

caused by a broken catenary 


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Heavy fire damage – Combino Amsterdam 

Happened: 

� 2002 in Amsterdam, Netherlands 

Damages: 

� Fire damage of the complete roof section 

� Caused by broken catenary 

� Gutted traction container 

Challenge: 

� Decontaminate of interior cabin equipment 

� Dismantling of complex roof and side wall bonding 

Activities: 

� Decontaminate of complete interior 

� Decontaminate of components 

� Re-wiring 

� Construction of new roof section 

� Complete electrical commissioning 


� April 2003 until June 2003 

I MO RS IS 



Accident repair after a fire-damaged Combino 

caused by a broken catenary 


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I MO RS IS 



Workshop Services is active around the world in 

Crash & Accident Repairs and Modernization 

Workshop Services: In our own facilities, customer‘s or partnered workshops 

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� Complete solution from one hand 

� Repair of damaged vehicles in a Siemens or customer owned facility 

� As consultant or as performer 

� Front, side crash or fire damage – all accidents 

� Trams, metros or trains – all vehicles 

� Support to enhance the operational lifetime 

� Restoration of historical cars 

� Modifications as a complete solution 

� Individual support like supervision, engineering or commsioning 

� Qualified staff for overhauls 

I MO RS IS 

Crash & Accident Repair 

Modernization 



A second life or simply modification for rail 

vehicles with modernization solutions of Siemens 

Overview on modernization services 

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Modernization 

Content 

Modernization of complete fleets to enhance the operational 

lifetime as well as restoration of historical vehicles 

� Creation of retrofit concepts (technique, design, costs) 

� Set-up of retrofit schedule 

� Engineering of components and software 

� Procurement of new components 

� Execution of retrofit work (disassembly, new components, 

welding, painting, finishing) 

� Commissioning and acceptance tests 

� Complete retrofit documentation 

Additional restoration activities 

� Assessment of condition of all components 

� Cleaning of the vehicle 

� Restoration of components 

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Interior retrofit 

Assembly of new components 

Benefits 

� Customer specific solution on site or at our own facilities 

� Modification of one vehicle or of a fleet 

� Complete order processing including logistics, engineering, 

approval and documentation Underfloor retrofit 



Modernization of Rolling Stock is multifaceted 

Examples for modernization 

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Combino Budapest Metro Munich 

Desiro UK class 450 

Locomotive BR 189 

� Installation of a new 

air conditioning system 

� Syntegra prototype 

including installation of 

traction converter & bogie 

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� Change of interior alignment 

for upgrading passenger 

Capacity 

� Retrofitting of ATC systems 

for cross border operation 

(e.g. ETCS, ATB, SCMT) 



Retrofit of an air conditioning system 

for Combino Budapest 

Example for installation of new components on site 

Type of vehicle: 

� Air conditioning units 

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Air condition system 

Customer requirements: 

� Demounting of the existing system for heating and ventilation 

� Adaption of interfaces 

� Assembly of new air conditioning system 

Activities: 

� Pre-assembly of cables and connectors 

� Disassembly of existing system and interior flaps 

� Mechanical works including drilling of holes and sealing 

� Change of control cables and installation of new cabling 

� Assembly of new air-conditioning unit 

� Installation of a separate DC/DC converter 

� Check of insulation and water tightness 

� Commissioning including check of functions 

� Type test to confirm the technical data and cooling power 

Duration of modernization service 

� February 2008 until June 2008 

Amount: 

� 120 at 40 Combino 

trams 

I MO RS IS 



Retrofit of an air conditioning system 

for Combino Budapest 

Example for installation of new components on site 

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I MO RS IS 



Syntegra – Complete retrofitting of a Munich metro 

train with a new traction system and bogie 

Syntegra prototype modification 


� Munich metro train 

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Upgrade Syntegra 


� Disassembly of existing traction system and bogies 

� Mechanical and electrical adaption for new systems 

� Engineering, welding, commissioning and documentation 

Activities: 

� Transport of end car to Siemens workshop 

� Mechanical and electrical disassembly 

� Engineering and calculation 

� Mechanical adaption for new traction system and bogie 

including welding, drilling, painting, cablings etc. 

� Assembly of new components and connection of bogie, 

traction, cooling, braking and other electrical systems 

� Check of insulation and commissioning 

� Documentation of works 


� June 2005 until January 2006 

Amount: 

� 1 

I MO RS IS 



Syntegra – Complete retrofitting of a Munich metro 

train with a new traction system and bogie 

Syntegra prototype modification 

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I MO RS IS 



The new requirements regarding cross border 

operation can be fulfilled with an ETCS upgrade 

ETCS upgrade 


� Locomotives BR 189 (Mitsui) 


� Disassembly of existing ATC-systems 

� Adaption of mechanical and electrical interfaces 

� Installation of new components 

Activities: 

� Transport of locomotives into Siemens workshop 

� Mechanical and electrical disassembly 

� Mechanical adaption for new ATC-components 

� Assembly of new components and connection of cables 

(e.g. displays, sensors, electrical cabinets, antennas) 

� Assembly of new pantograph 

� Check of insulation 

� Commissioning including driving tests 

� Documentation of works 


� December 2007 until end of 2010 

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ETCS-Upgrade 

Amount: 

� 85 

I MO RS IS 



The new requirements regarding cross border 

operation can be fulfilled with an ETCS upgrade 

ETCS upgrade 

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I MO RS IS 



The ‘High Capacity’ project for 

Desiro trains class 450 at Bournemouth depot 

Interior modification 


� Desiro class 450 

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High capacity modification 


� Interior retrofit to improve the transport capacity 

� Planning of new outline for several types of cars 

� Execution of works at Bournemouth depot 

Activities: 

� Disassembly of the existing seat modules (3 seats) 

� Remove of big litter bins, tables and curtains 

� Mechanical works on the floor (e.g. holes, carpet) 

� Installation of new seat modules (2 seats) 

� Assembly of new side handrails 

� Reworking of interior doors 

� Installation of small litter bins behind glass divider 

� Sealing of holes that are no longer used 

� Repair of carpet 


� August 2007 until July 2008 

Amount: 

� 28 

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The ‘High Capacity’ project for 

Desiro trains class 450 at Bournemouth depot 

Interior modification 

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I MO RS IS 



The greater the challenge, the better we get – 

We keep rail systems running 

Copyright © Siemens AG 2009. All rights reserved.

SIEMENS Integrated Services - Presentation ... - Siemens Mobility

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