Rail versus Aerospace

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1 12 November 2013 Railway Interiors Expo, Cologne D Rail versus Aerospace a comparison By: Reinoud Hermans 2013 ADSE B.V. 1

2 Agenda Agenda 1. Introduction: Why this presentation? 2. Rail vs. Aerospace: Key Commonalities & Differences 3. Design Example: Lavatory 4. Design Example: Seats 5. Design Example: Luggage 6. Suppliers in Rail & Aerospace 7. Final Remarks & Conclusions 2013 ADSE B.V. 2

3 1. Introduction About ADSE Independent Consulting & Engineering since 1996 Markets: Rail, Aerospace, Defense EASA Approved Design Organization & Qualified Entity We apply & share best practices across market domains Our Added Value Specification, integration and certification of technical solutions Hands-on make-it-work approach: We structure, develop & find solutions together with our customers 2013 ADSE B.V. 3

4 1. Introduction A D S E H o l d i n g : A D S E B V, H o o f d d o r p ( N L ) M o v i n g D o t, H o o f d d o r p ( N L ) A D S E A G, R e i n a c h ( C H ) 2013 ADSE B.V. 4

5 1. Introduction About me Since 1999 at ADSE Consulting & Engineering, NL Projects in Aerospace: Commercial interiors VIP conversions Certification Projects in Rail: Interior modernization of rolling stock Reliability performance and life cycle cost (RAMS/LCC) 2013 ADSE B.V. 5

6 1. Introduction Why this presentation? Rail and Aerospace have many things in common Interiors in Rail and Aerospace are very different What drives these differences? What can we learn from the differences and the similarities? This presentation is about Interiors 2013 ADSE B.V. 6

7 1. Introduction Rail & Aerospace, Two different Worlds? Gisborne, New Zealand 2013 ADSE B.V. 7

8 2. Rail vs. Aerospace What do Rail and Aerospace have in Common? Train = A set of interconnected busses on rails Airplane = A pressurized bus in the air 2013 ADSE B.V. 8

9 2. Rail vs. Aerospace What are Key Differences between Trains and Airplanes? A. Across the Border: Airplanes can fly between continents, all over the world. Harmonization is vital. B. Fire Safety: Airplanes don t fly through tunnels C. Social Control: Trains are open to the general public and typically don t have cabin attendants D. PRM: Trains are far better equipped for Persons with Reduced Mobility (PRM) E. Weight: Weight and range of an airplane have a direct link: An airplane flies further with a lighter interior What are the consequences of these differences? 2013 ADSE B.V. 9

10 2. Rail vs. Aerospace A. Across the Border: Harmonization Rail: Early interoperability standards for rail date back to Well before the Wright brothers flew the first powered aircraft in 1903 Today, rail regulations are still dominated by national standards Example: Many different standards for platform heights. Example: Today 5 different national standards for fire safety exist (British, French, German, Italian, Polish) New EU standard EN45545:2013 mandatory from ADSE B.V. 10

11 2. Rail vs. Aerospace A. Across the Border: Harmonization Aerospace: Harmonization between countries is vital in a global aviation industry There is complete harmonization within Europe (EASA) and between Europe and the United States (FAA). ICAO (International Civil Aviation Organization) coordinates world wide harmonization of aircraft operations. Lessons learned from incidents and safety findings are shared world wide 2013 ADSE B.V. 11

Arvika, Sweden Rail: Train coaches are often separated by doors, which gives passengers

12 2. Rail vs. Aerospace B. Fire Safety Requirements (Tunnels) Full-scale fire test in train tunnel METRO project. Arvika, Sweden Rail: Train coaches are often separated by doors, which gives passengers a temporary escape. Requirements assume possible long evacuation times. Consequently, toxicity requirements get high attention ADSE B.V. 12

13 2. Rail vs. Aerospace B. Fire Safety Requirements Aerospace: Requirements revolve around first 90 sec. after incident. Focus is on smoke density requirements. Strict rules for mat. and locations that can t be reached in-flight, e.g. thermal & acoustic insulation, cargo comp. Requirements for the intensity in which cabin materials release their energy in case of fire (heat release). No requirements from authorities for toxicity! Only from aircraft manufacturers (e.g. Boeing, Airbus, etc.) Don t forget: Airplanes carry their own fuel! 2013 ADSE B.V. 13

14 2. Rail vs. Aerospace B. Fire Safety Requirements Everybody survived! Air France A340, Toronto, Canada (2005) On board: 297 passengers & 12 crew ADSE B.V. 14

15 2. Rail vs. Aerospace C. Cabin Attendants: Role in Cabin Rail: Trains have no cabin attendants overlooking all passengers. Consequently, the lack of social control makes railway interiors vulnerable to vandalism. Aerospace: Cabin attendants play a vital role in passenger safety and play an active role during evacuations. Their presence makes vandalism in Aerospace rare ADSE B.V. 15

16 2. Rail vs. Aerospace D. PRM: Accessible Lavatories Rail: National PRM standards exist for decades. European PRM standard since Facilities for people with disabilities, like accessible lavatories, ramps and braille signs, very common in rail. Aerospace: Requirements for Persons with Reduces Mobility in aerospace only exist since 2009! They require an accessible toilet is available in wide body (dual aisle) aircraft. The rail sector is far ahead on this subject! 2013 ADSE B.V. 16

17 2. Rail vs. Aerospace E. Weight: Range, Center of Gravity, Payload Rail: To a certain extend, weight is necessary for correct axle loads and center of gravity Payload: between 15 and 20 % of total weight Aerospace: Center of gravity is very critical w.r.t. safe operation Weight is directly linked to range: Airplanes are only cost-effective if they are as light as possible Payload: between 20 and 25 % at take off (figure improves during flight with fuel burn!) 2013 ADSE B.V. 17

18 2. Rail vs. Aerospace E. Weight: Range, Center of Gravity, Payload 2013 ADSE B.V. 18

19 2. Rail vs. Aerospace What are the Main Design Drivers for Interiors? Rail Vandalism and cleanability People with reduced mobility Tunnel safety in relation to fire worthiness Weight and energy conservation only recently a topic of interest Aerospace Weight Fire safety Crashworthiness How can we inspire each other? 2013 ADSE B.V. 19

20 2. Rail vs. Aerospace 2013 ADSE B.V. 20

21 3. Design Example: PRM Lavatory Rail solution for Persons with Reduced Mobility (PRM) Design represents minimum space solution of PRM lavatory for rail applications. Regulations assume completely autonomous use by traveler with wheel chair ADSE B.V. 21

22 3. Design Example: PRM Lavatory Rail solution for Persons with Reduced Mobility (PRM) 2013 ADSE B.V. 22

3. Design Example: PRM Lavatory Aerospace solution for Persons with Reduced Mobility (PRM) Design concept with foldable partition to convert two single lavatories into

23 3. Design Example: PRM Lavatory Aerospace solution for Persons with Reduced Mobility (PRM) Design concept with foldable partition to convert two single lavatories into one large PRM lavatory. ~ 675 mm Meant for wide-body aircraft, located between cabin aisles. Regulations assume assistance for traveler with wheel chair ADSE B.V. 23

24 3. Design Example: PRM Lavatory Aerospace solution for Persons with Reduced Mobility (PRM) Airbus A320 narrow body. TAM Airlines (Brazil). Two single lavatories One PRM lavatory 2013 ADSE B.V. 24

25 3. Design Example: PRM Lavatory Conclusion: Aerospace is far behind compared to Rail An airplane passenger still needs assistance to use the PRM lavatory But due to very limited space, aerospace solutions for PRM lavatory are very creative 2013 ADSE B.V. 25

26 4. Design Example: Seats Rail 20 kg per passenger Mostly aluminum alloy frame. Sometimes steel. Typically floor + sidewall mounted. Sometimes free hanging from sidewall. Fixed position Shall meet 3g or 5g forward static load requirements Cost: ±300,- per passenger 2013 ADSE B.V. 26

4. Design Example: Seats Aerospace 12 kg per passenger. Aluminum base frame. Typically two legs on seat track. Sometimes, one seat stack is on sidewall.

27 4. Design Example: Seats Aerospace 12 kg per passenger. Aluminum base frame. Typically two legs on seat track. Sometimes, one seat stack is on sidewall. Flexible position Shall meet 16g forward dynamic load req s. Baggage restraint under seat. Cost: ±2000,- per passenger Source: RECARO 2013 ADSE B.V. 27

28 4. Design Example: Seats Why are railway seats so much heavier than aircraft seats? Much higher resistance against vandalism Sidewall mounting and cleanability increases weight Passenger comfort often higher than aircraft seats Trains run forward and backward. Airplanes only fly forward (backward crash load condition: only 1.5g) Why are aircraft seats so much more expensive? 16g dynamic load: engineering & test process Very challenging weight targets Very demanding certification & production paperwork 2013 ADSE B.V. 30

29 4. Design Example: Seats Conclusion Weight savings come at a very high price! Differences in requirements between rail and aerospace are enormous Railway seats have to be much more resistant against contamination, cleaning and vandalism than airplane seats The rail industry can benefit from experience of aerospace w.r.t. development methods for light-weight design 2013 ADSE B.V. 31

30 5. Design Example: Luggage Luggage in Trains Typically, no dedicated, closed cargo compartment Very few rules and regulations w.r.t. weight and sizes Luggage in passenger compartment mostly poorly restrained Bangkok (2013) 2013 ADSE B.V. 32

5. Design Example: Luggage Luggage in Aircraft Dedicated cargo compartments under cabin floor prevent heavy items flying through the cabin Over-head stowage

31 5. Design Example: Luggage Luggage in Aircraft Dedicated cargo compartments under cabin floor prevent heavy items flying through the cabin Over-head stowage compartments and stowage under the seats are designed to restrain luggage during crash Restrictions w.r.t. size & weight for carry-on luggage 2013 ADSE B.V. 33

32 5. Design Example: Luggage Trade-off: Safety vs. Design In modern train interiors, design and aesthetics sometimes seem to get a higher priority than safety. Conventional Modern 2013 ADSE B.V. 34

33 5. Design Example: Luggage Conclusion Due to the nature of rail transport, luggage in train compartments will always remain a primary hazard in case of an accident ICE, Germany Luggage stowage ICE, Germany Folding bicycle 2013 ADSE B.V. 35

34 6. Suppliers in Rail & Aerospace Only very few companies serve both the rail and aerospace market with the same products. Examples: Sabic Thermoplastics Botany Weaving, Forbo and Schneller flooring products Zodiac (EVAC) toilet systems Aerolux galley equipment Bombardier builds both trains and aircraft, but in completely separate plants and with different processes. Why so few? Synergy is difficult due to very different requirements. Production from same production line almost impossible ADSE B.V. 36

35 7. Final Remarks & Conclusions RAMS/LCC: Reliability, Availability, Maintainability & Safety (RAMS) and Life Cycle Cost (LCC) are common topics in aerospace. They only recently get attention in rail. Certification: Aerospace has very accurately defined certification procedures and means to show compliance. In Aerospace, the supply chain shares the certification responsibility ADSE B.V. 37

36 7. Final Remarks & Conclusions What Rail can learn from Aerospace? Learn from design methods, for instance to save weight. Application of end products like seats is not a logical route due to vast differences in requirements. Harmonization and co-development is far more advanced in aerospace. It makes requirements much more clear and integration less of a gamble. Passive safety for passengers has much more attention in aerospace. What Aerospace can learn from Rail? Facilities for Persons with Reduced Mobility are far more mature in rail ADSE B.V. 38

37 7. Final Remarks & Conclusions What will the Future of Rail Transport look like? Levitation train concept, Japan ADSE B.V. 39

38 D Thank you A d d r e s s : S c o r p i u s L R H o o f d d o r p T h e N e t h e r l a n d s C o n t a c t : r e i n o u d. h e r m a n a d s e. e u w w w. a d s e. e u 2013 ADSE B.V. 40

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