ETCS Integration Design for Class 66 Locomotives

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Article: ETCS Integration Design for Class 66 Locomotives

Overview

DB ESG received an order from Siemens Mobility to supply the vehicle installation design to integrate Siemens Trainguard 200 European Train Control System (ETCS) onto UK freight locomotives.

This project forms part of Network Rail Digital Railway’s ETCS Freight Train Fitment Programme. Siemens Mobility is contracted to Network Rail for the provision of firstin-class design and fitment of Siemens’ ETCS Trainguard 200® on-board equipment onto the locomotives.

Siemens has subcontracted DB ESG to provide the mechanical and electrical vehicle installation design and first-in-class support of an ETCS Level 2 on-board and TPWS/AWS solution for several locomotive classes, including Class 66, Class 60, Class 57, and Class 47. This case study will focus only on the Class 66 project.

The Class 66 project is the most complex Class within DB ESG’s scope to complete because, not only are there 416 Class 66 locomotives included within the scope of the integration design, but within this class of vehicle there are 45 locomotive design variants. These variants presented a significant volume of work in identifying the impact of each variant to the core design, resulting in 31 unique installation design variants across more than 800 drawings. The Class 66 locomotives, including variants, are also owned by seven different organisations, and operated (in the UK) by five different Freight Operating Companies (FOCs), all of which result in a complicated stakeholder interface and requirements management.

Work Undertaken by DB ESG

  • The design of all equipment mechanical mounting arrangements including brackets and frames required.
  • Detailed mechanical drawings for all manufactured items.
  • Production of general assembly drawings for both pre-assembly and complete assembly items.
  • Creation of harness drawings and details of all inter-connecting cables, including system wiring between ETCS equipment, jumper cable assemblies and all other wiring required for interfaces.
  • Electrical schematics that detail all connections to new and existing equipment.
  • Vehicle upgrade designs for AWS/TPWS Fourth Generation and other vehicle systems.
  • Vehicle power assessment.
  • Completion of vehicle modification procedures.
  • Human factor assessment work (cab, desk, environment and maintenance) carried out for each stage – Survey, Concept, Preliminary and Final Stages), with reports produced for each stage.
  • Creation of a cable and equipment Installation and Test Specification, including cable screen continuity/isolation tests, insulation tests, point to point continuity tests, earth bond tests and VSWR tests.
  • Mechanical calculations for equipment mounting.
  • Electrical protection, cable rating and earth bonding calculations.
  • Materials inventory for all installation material.
  • Bill of Materials for all installation items.
  • Clause by clause response for all applicable standards.
  • Updated Vehicle Maintenance and Vehicle Overhaul Instructions including Maintenance Manual Addendums.
  • All drawings and documentation required to support the installation design approval process.
  • A cab mock-up.
  • First in Class and testing site support.
  • As built design drawings.
  • Specific assessments, including but not limited to: vehicle mass, gauging, radar assessments, RC2 and fire tests