Making Innovation Work: Using 3D CAD Virtual Prototype Evolution in Train Component Design

Cost has broad implications in rail, from the more obvious financial cost, to that of reputation, performance, staff engagement and customer perception. More prominent in rail is the cost of human life when operations... [ view full abstract ]

Cost has broad implications in rail, from the more obvious financial cost, to that of reputation, performance, staff engagement and customer perception. More prominent in rail is the cost of human life when operations tragically result in accident and/or injury. Designing components to engineer out potential faults and improve human-system integration is becoming increasingly vital in ensuring optimal performance is obtained while preventing potential for error and faults. Virtual innovation provides a means to assess system design and effectiveness, reducing a projects financial burden while minimising exposure to risk.

Introducing new or remodelled equipment is a perpetual process in the rail industry, driven by technological advancement, changing regulatory requirements or human factors/safety advancements. Ensuring infrastructure on-track is of a high standard comes at a cost to rail operators, whether it is associated with the creation of prototypes, user testing or more drastically the cost of repairing damage caused by introducing a poor design into the network.

Designing equipment to fit the human, and testing for human factors integration through the use of virtual CAD modelling early in the design process can significantly minimise the cost associated with its introduction. Such a virtual modelling approach also facilitates a cost efficient method to consider alternate innovative concepts that may not have been possible to explore using more traditional prototyping methods.

Virtual emulations of the proposed equipment can be tested through modern 3D modelling software, placing scale human models in train cab mock-ups to test sight lines, reach envelope, and human factors criteria before even picking up a hand-saw.

This process has been applied by Ergonomie in a range of projects, including the use of 3D modelling, and CAD software to virtually reproduce a range of Driver cab configurations for the introduction of ATP in the Oscar train. Multiple configurations were created with varying placement of in-cab equipment such as gauges and controls. A Human CAD mannequin was placed in the virtual cab 3D model to test visual lines of sight, reach to controls and positioning of critical controls and alarms.

Virtual modelling of train components and equipment to test human factors integration presents an opportunity to revolutionise the design process for introducing new train concepts. It opens up opportunities to test more concepts, allowing for variation and innovation without the cost of physical prototyping, and in a fraction of the time. Considering the implications of design decisions through CAD modelling presents a new approach to risk management, and more effective means of testing for potential sources of human error, injury or accident in our infrastructure out on the track.