The modification of a railway passenger coach involves structural changes to
the roof and the side wall to support the installation of a rooftop air-conditioning unit.
The modified structure requires verification of its structural integrity to ensure safe
operation. This verification is conducted in accordance with the European standard EN
12663, which defines the structural requirements for railway vehicle bodies. The
assessment is carried out using finite element analysis, focusing on static load cases
relevant to the modified area. Total of six static load cases were analyzed including
proof loads representing the structural effects of forces acting on the air-conditioning
unit attachment due to acceleration in the positive and negative x-, y-, and z-directions.
The analyses reveal that high-stress areas across all scenarios are predominantly located
at the connection between the newly installed crossbeam supporting the air-conditioning
unit and the longitudinal cant rail of the original passenger coach structure. Among these
scenarios, the load case involving acceleration in the negative x-direction (braking)
produced the highest von Mises stress of 207.4 MPa. This stress remains below the
material’s yield strength, ensuring a safety margin against plastic deformation under the
applied loading conditions. The remaining load cases also result in stresses within the
allowable range, confirming structural adequacy across all scenarios. In summary, the
modified passenger coach meets the relevant structural requirements defined in EN
12663 standard concerning static. The structure exhibits no permanent deformation
under the specified static load cases, confirming the structural adequacy of the
modifications.