Rolling stock testing

Ensure that your rolling stock vehicles and railway components meet safety requirements by complying with relevant regulations

What is rolling stock testing?

Rolling stock testing encompasses physical testing of rail vehicles and components to ensure they meet safety, performance, and regulatory standards. This includes both laboratory and on-track testing of rolling stock and individual components under real-world conditions.

Tests from an accredited test lab such as TÜV SÜD subject rolling stock vehicles and railway components to different scenarios, such as derailments or impact collisions, to assess their durability and safety. We test with a thorough understanding of the latest updates in railway testing such as advancements in simulation technology, improved testing methodologies, and enhanced regulatory requirements.

Why rolling stock testing is important

Rolling stock testing ensures that both the rolling stock and rail components are safe in accordance with relevant global standards and regulations.

By conducting physical tests under realistic operating conditions, as well as under extreme scenarios such as derailment safety tests, rail crash tests, or impact tests, valuable results and insights can be gathered. Once the tests are completed, you can use these results as a basis for commissioning approval, certification, or necessary improvements.

Furthermore, rolling stock testing can help to identify safety issues and performance weaknesses early in the development process. This can help you avoid costly rework and delays in development and deployment of rolling stock.

The integration of modern technologies and simulation methods presents both opportunities and challenges. While these technologies can enhance testing accuracy and efficiency, they also require substantial investment and expertise. You need to navigate the complexity of integrating new technologies into existing testing processes. It is also vital to train your personnel adequately to utilise these advancements effectively.

A further challenge is that rail vehicles and rail components are diverse, ranging from high-speed trains to freight cars. Each type of vehicle or component may have specific testing requirements and performance criteria. This necessitates specialised knowledge and tailored testing approaches for each type of rolling stock.

How TÜV SÜD can help you with testing of railway vehicles, railway infrastructure or rail components

TÜV SÜD possesses a deep understanding of regulatory requirements, combined with our expertise in testing rolling stock and rail components.

Our testing facilities for rolling stock and components are located in Halle/Saale, Görlitz, and Berlin in Germany, as well as in Winterthur, Switzerland.

At our Görlitz location, we are equipped with testing facilities covering an area of about 50,000 m², allowing for speeds of up to 60 km/h. This range provides ample speed for a variety of testing scenarios. We conduct on-track tests for various types of rail vehicles—ranging from auxiliary vehicles to high-speed trains—covering running dynamics, brakes, fatigue strength, pantographs, acoustics, machine dynamics, aerodynamics, heavy current, and electromagnetic compatibility for our global customers at our branches in Halle/Saale, Berlin, and Winterthur (CH). For these tests, we use the public railway networks or non-public test infrastructures (test rings).

In addition to testing your rail vehicles and components, we can also perform development tests for your vehicles and components. We evaluate the integration of modern testing methods with simulations and the interaction between pantographs and overhead contact lines.

Our expertise makes us a trusted authority. With a twist test rig for safety against derailment procedures in accordance with EN 14363, as well as the determination of inclination coefficients and swing poles, we are dedicated to meeting the high-quality requirements of the railway industry.

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What our rolling stock testing services include

We are accredited as a test center in accordance with DIN EN ISO / IEC 17025 and certified for brake and wheel slide protection tests by the UIC, as well as for dynamic overrun impact tests on tank containers and MEGCs (Multiple Element Gas Containers) by Transport Canada.

Running dynamics

We provide optimised stationary tests and on-track tests, which we also combine with simulation calculations:

Tests of safety against derailment of the various procedures according to EN 14363 (twisted and flat 150 m curved measuring track, 150 m S-bend and 450 m curved crossing).
Tests of driving safety under longitudinal compression forces according to EN 15839.
Running dynamics tests using the normal method with measuring wheel sets or the simplified procedure as per EN 14363 or UIC 518.
Application and calibration of instrumented wheelsets.
Integration of simulation calculations as per EN 14363.
Wheel and rail profile measuring to determine the real equivalent conicities as per EN 15302.
Whole-body vibrations as per ISO 2631.
Ride comfort for passengers as per EN 12299.
Determination of the vehicle parameters inclination coefficient, roll pole height, spatial centre of gravity and twist coefficient of the vehicle body.
Investigations of the freedom of movement in different track geometries and on the 3,5° ferry ramp.
Rolling stock-related measurements on infrastructure (track profile, etc.).

Brake system

Vehicle brake equipment checks and conformity with the equipment documentation.
Testing of brake control and brake mechanics (including lining or brake pad force measurements).
Brake assessment as per UIC 544-1 / EN 16834 (travel at own speeds and uncoupling tests).
Slide protection (WSP) tests (UIC 541-05 / EN 15595).
Testing of stopping reliability / break-away force of the parking brakes.
Functional tests and checks of vehicle diagnose systems.
Our extra service for you: Loading and weighing.

Fatigue strength tests

Fatigue strength is tested according to EN 12663-1, -2, EN 13749, ERRI B12 / RP 17, UIC codes, and technical specifications for interoperability as well as DVS guidelines, Eurocodes, IIW and FKM recommendations. We measure expansion/tension, forces, relative paths, accelerations:

Fatigue strength testing on traction and buffing gear (EN 15551, EN 15566).
On-track testing of running gear and its components as per EN 13749.
On-track testing of torsional vibrations (by measuring torsion and bending) on the wheel set according to German regulations (DIN 491/1).

Aerodynamics

Track tests for the approval of railroad vehicles according to EN 14067-4 and EN 14067-5.

Pressure changes and air flows next to the track.
Aerodynamic loads in the track bed.
Evaluation of running resistance.
Aerodynamics in tunnels.

EMC and Electrical Measurements

Measurements of voltage, current and magnetic fields for approval tests of rolling stock and infrastructure.

Verification of compatibility with track switching equipment

Interference currents according to EN 50238-2
Magnetic fields according to EN 50238-3

EMC radiation according to EN 50121-3-1.
EMC person safety according to EN 50500.
Proof of freedom from mains interference (admittance measurements).
High voltage and high current tests.
Drive dynamics (Z-V diagram), power supply and energy consumption.

Acoustics

Measurement of noise inside and outside of rail vehicles for approval according to TSI Noise. Measurements are carried out at downtime or during driving tests according to EN ISO 3095 and EN ISO 3381.
Measurement of roughness of wheels and rails according to EN 15610 and track decay rate according to EN 15461.
Vibration measurements in the vicinity of railroad tracks according to DIN 4150-2 and DIN 45672-1 to characterise the emission, transmission, and impact of vibrations and to predict vibration effects on people living near railroad installations according to DIN 4150 1.
Noise and vibration measurements at operator positions in regard with person safety according to EN 12096, ISO 5349 (human exposure to hand transmitted vibration) and ISO 2631 (human exposure to whole-body vibration)
Sound power and vibration measurements for the assessment of occupational safety.
Localisation of sound sources (including passing vehicles) by means of an acoustic array (112 microphones). The array samples with standard of 48 kHz and 24-bit resolution and has a dynamic evaluation range of up to 40 dB.
Measurements and examinations of machinery and equipment to determine noise emission and develop noise abatement and sound insulation measures.

Electrical lighting

Measurement of luminance, illuminance and glare
Measurement of colour spectra, correlated colour, colour coordinates, temperature, colour rendering

Pantograph tests

To optimise testing methods, we continuously develop measuring technology which leads to shorter test and evaluation times. The latest measuring technology can provide meaningful test results on site. Pantograph monitoring measurements can be performed at any time during running dynamic test runs. We perform the following tests as per EN 50317 to test the interaction between pantograph and overhead lines:

Measurements for the aerodynamic optimisation.
Contact force measurements.
Arc detection measurements.
Camera monitoring.
Stationary and mobile optical contact wire uplift measurement at the base and in the free field.

Machine dynamics

With our services in the field of machine dynamics and acoustics, we can handle any task involving vibrations and noise. Our claim is not only to describe a dynamic or acoustic problem by measurements, but to identify the cause by considering all relevant aspects and, based on the results, to develop countermeasures to solve the problem.

Measurement and diagnosis of vibrations.
Experimental modal analysis.
Operational vibration analysis.
Design of machine foundations and isolations.
Model-based simulation of machines and processes.
Acceptance measurements and assessment of vibration levels according to common standards.
Signal analysis for solving complex dynamic problems.

Component testing for traction and buffer equipment

For static/dynamic testing of traction and buffer equipment we have test rigs for loads up to 3 MN and an extensive carriage fleet with variable carriage weights. We offer tests for:

Side and diagonal buffers, collision-proof buffers (EN 15551), dampers.
Traction equipment, draw hooks, screw couplings (EN 15566).
Coupling system.

Crash tests (Front structures, crash elements)

Proof of crashworthiness for railway vehicle bodies and dynamic properties as well as the function of crash systems in cornering collisions (EN 15227).
Determination of static and dynamic properties of crash components and systems as per type test specifications.

HAZMAT containers and flexi tanks

We offer dynamic impact tests on tank containers, MEGCs and flexi tanks of various sizes, and testing of methods of securing loads in freight containers, either according to the applicable standard or in line with individual customer specifications. Our test services comprise the measuring and assessment of accelerations (SRS), forces, expansions and deformations of:

Tank containers (CSA B625, ISO1496-3, UN/ IMDG/ ADR/ RID Manual of Tests and Criteria).
Flexi tanks (PAS1008, COA Code of Practice).
Securing loads (customer-specific requirements).

Test coordination

We provide an experienced test coordinator who will handle your type tests professionally and ensure that everything runs smoothly. Our test manager helps you with:

Coordination/planning the vehicles involved in the test process after they have been transferred to the testing facility.
Determining the necessary vehicle states and coordinating any measures as part of the handover.
Clarifying and coordinating any problems with the vehicle.
Taking care of the track infrastructure, procuring track data, the timetable and the vehicles, and coordination with the rail company involved (network access, approvals etc.).
Mediating between you and other participants who are yet to be defined (TÜV SÜD, experts).
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