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Customer Challenge

We helped a manufacturer meet requirements set out by the Driver’s Council to ensure three variations of trains operating in the West Midlands met the highest possible standards.


In order to improve the driver’s forward sightlines and increase space round their seat, the new design had to extend cab length by 200mm, bringing the seat 50mm forward.
 

All this had to be delivered to meet tight production deadlines to ensure the rail network’s services progressed as planned.

Scope

  • To generate interior concept design for all the areas of cab except ceiling, floor, and driver’s desk
  • Co-ordinate with suppliers of GRPh formed parts and other parts to develop a suitable design for the complete cab
  • Develop acoustics and thermal insulations covering 80% of area
  • Review and release design through CDR/PDR/DDR design reviews gates with all stake holders

Solution

  • Develop surface models based on interface design description’s primary input for sidewalls, wind trims, knee well trims etc for driver and non-driver’s side
  • Create space envelop models and drawings for supplier parts like cab heaters and share this information with suppliers
  • Jointly investigate with suppliers the possibilities of interfaces on the primary structure for bought out items

Features

  • Generated alternate concept ideas considering features including car body, exterior GRPh structures, ceiling, driver’s desk and more
  • Validated design proposals with initial designs, supplier, methods & maintenance and human factors teams to assess manufacturability
  • Created interface control documents (ICDs). These described all interfaces for ease of installation and maintenance.
  • Validated the final design through prototype (physical mock-up) made by supplier.

Benefits

  • The sidewalls trims, wind trims, knee well trims, acoustics, thermal insulations and more have been designed as per UIC 651 standards for driver and non-driver’s side of the cab interior
  • Interface Control Document (ICD) and 3D models were prepared to provide detail for all scope of work
  • Acoustics and thermal insulations covered 85% of the free area
  • All interior trims and brackets have been designed to fit with car body tolerances as per EN ISO13920:1996
  • The design is compatible with ceiling and driver’s and non-driver’s desk interfaces
  • Common cab interior design has been achieved for all three trains of metro, outer suburban and long distance

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