Details

Overview
The CCB Burn Test Rig is a turnkey, fully pneumatic platform designed for comprehensive burn-in and functional testing of Central Control Block (CCB) electronic brake controllers.

By simulating the pressure cycles and electrical loads these controllers experience in real-world rail and automotive braking systems, the rig precipitates early-life failures, validates design robustness, and guarantees long-term reliability before units are released into
service.

Key Features & Capabilities
- Multi-Channel Burn-In: Simultaneously tests up to four CCB controllers, maximizing throughput.
- Precision Pressure Control: High-accuracy regulator delivers 0–16 bar air pressure with Class 0.05 dual-scale gauge (0–16 kg/cm2 | 0–220 PSI).
- Staged Reservoir Array: Eight stainless-steel tanks (two × 25 L, five × 13 L, one customer-provided 13 L) ensure stable pressure between cycles.
- Rapid UUT Hookup: BSP quick-release couplings (11⁄2′′, 1′′, 1⁄2′′, 1⁄4′′) and 3 m braided hoses on reels enable fast changeovers.
- Compact Mobility: All components—filters, valves, gauges, power supply—are mounted on a wheeled extruded-aluminum frame for easy relocation.
- Integrated DC Power: Dual-output 0–120 V DC @ 7 A supply powers controller electronics under test.

Components & Technical Specifications

  

    

      
Component
      
Description
    
  
  

    

      
Air Filter & Regulator
      
1″ line (adaptor to 1½″), 0–12 bar regulator
    
    

      
SS Reservoirs
      
25 L (2) & 13 L (5) rated 10 bar (tested to 16 bar)
    
    

      
Valves (Cocks)
      
1½″, 1″, ½″, ¼″ sizes, 10 bar line pressure
    
    

      
Safety Valves
      
¼″ spring-loaded set at 10 bar
    
    

      
Pressure Gauge
      
Dual-scale 0–16 kg/cm² | 0–220 PSI, LC 0.05, ±0.25% accuracy
    
    

      
Couplings & Nipples
      
BSP-threaded (1″, 3/8″, 1/4″) quick-release couplings & matching nipples
    
    

      
Hoses
      
BSP female swivel 1½″, 1″, ½″, ¼″; 3–4 m length; 10 bar rated
    
    

      
Calibration Port
      
¼″ Minimess coupling for external calibration
    
    

      
Control Panel & Frame
      
Extruded-aluminum with four wheels; custom layout for regulator, gauges, hose reels
    
    

      
DC Power Supply
      
Dual-output 0–120 V DC, 7 A
    
  


Operational Guidelines
Do’s
- Keep hoses, reservoirs, and fittings clean and debris-free.
- Confirm inlet air supply integrity and zero leaks before pressurization.
- Adhere to the prescribed test sequence and timing.
- Verify correct valve positions (open/closed) per test setup.
- Monitor gauges and digital indicators throughout testing.

Don’ts
- Never disconnect hoses under pressure.
- Do not perform maintenance until the system is fully vented.
- Avoid introducing contaminants into air lines or tubing.
- Do not operate with loose or damaged connections.

Maintenance & Calibration Schedule

  

    

      
Interval
      
Actions
    
  
  

    

      
Before/After Each Use
      
Visual inspection; confirm gauges read zero; check for leaks.
    
    

      
Monthly
      
Leak check tubing/piping; clean exterior; verify filter/regulator performance.
    
    

      
Every 3 Months
      
Inspect inlet line; clean filter element; torque-check all fittings.
    
    

      
Every 6–12 Months
      
Full-pressure leak test; calibrate/replace gauges and transmitters; replace pneumatic components; in-situ relief valve checks.
    
    

      
Every 5 Years
      
Overhaul major assemblies—flow meters, relief valves, regulators; replace piping as needed.
    
  


Safety & Compliance
High-Pressure Precautions: Only qualified personnel; follow LOTO and high-pressure safety protocols.
Certified Components: All gauges supplied with traceable calibration certificates; complies with EN 50155, IEC 61373 and other relevant standards.
Documentation Package: Comprehensive operation, troubleshooting, and maintenance manuals included.

Applications
The rig seamlessly integrates into OEM production lines for 100% burn-in and design verification, and into Tier-1 supplier quality-assurance workflows for batch testing and incoming inspection. Railway operators and depots use it for in-service health checks,
refurbishment validation, and predictive maintenance. Independent labs leverage its multiunit capacity and data-logging for contract and standards-compliance testing, while R&D teams combine it with environmental chambers for advanced thermo-pneumatic stress screening and manufacturing process optimization.

Conclusion
By combining precise pneumatic control, robust modular design, and industry-proven burnin methodologies, the CCB Burn Test Rig delivers unparalleled reliability validation for brake controller electronics. It uncovers latent defects, enforces stringent safety standards,
and drives continuous quality improvements—ensuring

      


Advanced CCB Burn Test Rigs for Rail and Automotive Brake Controllers

Reliable performance of brake controllers is critical for rail and automotive safety. CCB Burn Test Rigs and pneumatic burn-in testers provide controlled environments for evaluating the endurance and functionality of brake controllers under repeated operational cycles. Brake controller test benches ensure precise testing of pressure response, timing, and reliability.

Modern setups include CCB endurance testing systems, multi-channel burn-in systems, and rail brake controller testers, enabling simultaneous testing of multiple units with high accuracy. Automotive brake controller burn-in rigs, combined with precision pressure cycling rigs, allow high-throughput evaluation while maintaining rigorous quality standards. These advanced test platforms ensure consistent, reliable, and safe brake controller performance across rail and automotive applications.