Test Bench for Indian Railway Air Brake system (IRAB)

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Technical Details

Specifications


  
    Parameter
    Specification
  
  
    Pneumatic Medium
    Filtered, oil-free compressed air
  
  
    Supply Pressure
    8–10 kg/cm² (nominal), max 10.5 kg/cm²
  
  
    Flow Capability
    70 CFM (2,000 LPM)
  
  
    DAQ Resolution
    24 bit, up to 1 kHz sampling per channel
  
  
    Gauge Accuracy
    ±0.5% FS
  
  
    Temperature Range
    0–48 °C ambient
  
  
    Power Requirement
    230 VAC ± 10%, 50 Hz, 5 kVA
  
  
    Footprint (WxDxH)
    1.5 m × 0.8 m × 1.8 m
  
  
    Weight
    ~650 kg
  
  
    Noise Level
    < 75 dB(A) at 1 m
  
  
    Software
    Windows 10 Pro, .NET Framework, SQL Server

Parameter	Specification
Pneumatic Medium	Filtered, oil-free compressed air
Supply Pressure	8–10 kg/cm² (nominal), max 10.5 kg/cm²
Flow Capability	70 CFM (2,000 LPM)
DAQ Resolution	24 bit, up to 1 kHz sampling per channel
Gauge Accuracy	±0.5% FS
Temperature Range	0–48 °C ambient
Power Requirement	230 VAC ± 10%, 50 Hz, 5 kVA
Footprint (WxDxH)	1.5 m × 0.8 m × 1.8 m
Weight	~650 kg
Noise Level	< 75 dB(A) at 1 m
Software	Windows 10 Pro, .NET Framework, SQL Server

• OEM Production Quality Control: Inline in locomotive and valve‐OEM assembly lines to validate each batch of pneumatic valves before installation. Automated pressure, flow, and leak tests ensure only components within tolerance proceed—minimizing rework and field failures.
• Depot Maintenance & Overhauls: Used in railway workshops for scheduled preventive maintenance and annual overhauls. Technicians diagnose worn or leaking valves, compare performance against “golden” curves, and generate audit‐ready reports for each valve.
• Field Commissioning & Turnkey Installations: Rapidly deployable with quick‐connect plumbing and detachable covers, the rig supports on‐site brake‐system commissioning for new or refurbished locomotives—verifying manifold, tubing, and control‐logic integrity under true supply pressures.
• Regulatory Certification & Compliance Testing: Executes RDSO, UIC, and EN endurance and safety protocols—including rapid charge, slow release, and high‐temperature cycling—and produces the full data logs and PDF documentation required for type‐approval and re‐certification.
• Research, Development & Accelerated Life Testing: Enables R&D teams and academic labs to validate new valve designs under accelerated aging, contamination, vibration, and thermal stress. Custom profiles capture minute changes in hysteresis, leakage, and response time over tens of thousands of cycles.
• Training & Skill Development: Employed in technical institutes and railway academies as a hands‐on teaching tool. Interactive software modules guide trainees through pneumatic principles, calibration exercises, and fault‐finding, building diagnostic competence in brake systems.
• Aftermarket Support & Spare‐Parts Validation: Independent service providers and spare‐parts distributors certify replacement assemblies against OEM benchmarks, comparing second‐source parts to original performance curves—ensuring equivalent or superior reliability and safety.

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Details

Introduction
The IRAB Brake System Test Rig from Neometrix is engineered to meet the exacting demands of modern electric locomotive maintenance and R&D. IRAB (“Independent and Release Brake”) systems rely on a network of pneumatic valves to control braking pressure, ensure fail‐safe operation, and enable dynamic brake release under a variety of operating conditions. By simulating real‐world supply pressures, flow rates, and temperature variations, this test rig replicates both routine service cycles and extreme fault scenarios— validating valve performance from initial actuation through full release. Its modular stainless‐steel enclosure and front‐end digital display panels keep all critical components accessible for rapid fault isolation and servicing, while a dedicated PC interface fully automates test sequences and archival reporting.

Key Features
▹ Comprehensive Valve Coverage: Tests 18 valve types across all IRAB sub-assemblies, including brake and safety valves.
▹ Precision Pneumatic Control: Dual 250 kW compressors hold 8–10 kg/cm² with ±0.02 kg/cm² stability.
▹ Advanced Data Acquisition: 24-bit DAQ samples at 1 kHz; logs graphs and trends to SQL for analysis.
▹ Automated Safety Interlocks: Relief valves, E-stop, and watchdog prevent overpressure and test drift.
▹ User-Friendly Software: RDSO-compliant recipes, one-click PDF reports with custom headers/footers.

Applications
• OEM Production Quality Control: Inline in locomotive and valve‐OEM assembly lines to validate each batch of pneumatic valves before installation. Automated pressure, flow, and leak tests ensure only components within tolerance proceed—minimizing rework and field failures.
• Depot Maintenance & Overhauls: Used in railway workshops for scheduled preventive maintenance and annual overhauls. Technicians diagnose worn or leaking valves, compare performance against “golden” curves, and generate audit‐ready reports for each valve.
• Field Commissioning & Turnkey Installations: Rapidly deployable with quick‐connect plumbing and detachable covers, the rig supports on‐site brake‐system commissioning for new or refurbished locomotives—verifying manifold, tubing, and control‐logic integrity under true supply pressures.
• Regulatory Certification & Compliance Testing: Executes RDSO, UIC, and EN endurance and safety protocols—including rapid charge, slow release, and high‐temperature cycling—and produces the full data logs and PDF documentation required for type‐approval and re‐certification.
• Research, Development & Accelerated Life Testing: Enables R&D teams and academic labs to validate new valve designs under accelerated aging, contamination, vibration, and thermal stress. Custom profiles capture minute changes in hysteresis, leakage, and response time over tens of thousands of cycles.
• Training & Skill Development: Employed in technical institutes and railway academies as a hands‐on teaching tool. Interactive software modules guide trainees through pneumatic principles, calibration exercises, and fault‐finding, building diagnostic competence in brake systems.
• Aftermarket Support & Spare‐Parts Validation: Independent service providers and spare‐parts distributors certify replacement assemblies against OEM benchmarks, comparing second‐source parts to original performance curves—ensuring equivalent or superior reliability and safety.

Technical Specifications

Parameter
Specification

Pneumatic Medium
Filtered, oil-free compressed air

Supply Pressure
8–10 kg/cm² (nominal), max 10.5 kg/cm²

Flow Capability
70 CFM (2,000 LPM)

DAQ Resolution
24 bit, up to 1 kHz sampling per channel

Gauge Accuracy
±0.5% FS

Temperature Range
0–48 °C ambient

Power Requirement
230 VAC ± 10%, 50 Hz, 5 kVA

Footprint (WxDxH)
1.5 m × 0.8 m × 1.8 m

Weight
~650 kg

Noise Level
< 75 dB(A) at 1 m

Software
Windows 10 Pro, .NET Framework, SQL Server

System Components
• Stainless‐Steel Enclosure: Corrosion‐resistant frame with roll‐out covers and integrated condensate tray.
• Air Preparation Unit: 5 μm prefilter, 0.01 μm coalescing filter, refrigerated dryer, and particulate filter to ISO 8573‐1 Class 1.
• PLC & DAQ Rack: Siemens S7‐1200 PLC for safety interlocks; NI DAQ for high‐speed data streaming to PC.
• Control Console: Industrial touchscreen for local overrides, status LEDs, and emergencystop.
• PC Workstation: High‐performance Dell machine running “CCUBTB” software; communicates via USB‐Ethernet module.

Operation Modes
Automatic Mode:
1. Select test recipe (valve type, pressure ramp, dwell times).
2. System purges and pre‐pressurizes to target.
3. Executes actuation sequence, records pressure curves and leakage.
4. Auto‐generates pass/fail verdict based on preset tolerances.

Manual Mode:
• Technician triggers individual solenoid or manual valve actuations via console toggles, with live pressure readouts for on‐the‐fly troubleshooting.

Calibration Mode:
• Disconnect reference sensors for comparison against certified gauges; software logs new calibration factors.

Software Interface & Reporting
• Main Dashboard: System health overview (pressure, temperature, compressor status) and test job queue.
• Recipe Editor: Create or modify test templates for new valve designs or updated standards.
• Data Visualization: Interactive XY plots of pressure vs. time, with measurement cursors for rise/fall times and hysteresis loops.
• Report Manager: Organizes PDF reports by date, operator, and serial number; supports CSV/Excel export.

Maintenance & Safety
Daily: Check dryer dew point, inspect filters, verify emergency‐stop functionality.
Weekly: Drain condensate traps, clean prefilters, review test logs for drift or leaks.
Monthly: Calibrate transducers against certified gauges; lubricate solenoids per supplier specs.
Annual: Neometrix‐certified technician conducts full audit, firmware/software updates applied.
Safety Protocols: Hearing protection required when compressors run; lock‐out/tag‐out procedures for internal service.

Conclusion
By combining precision pneumatics, rigorous safety interlocks, and an intuitive software suite, the Neometrix IRAB Brake System Test Rig delivers end‐to‐end validation of locomotive brake valves. Its automated workflows and comprehensive reporting not only streamline workshop throughput but also bolster operational reliability—safeguarding locomotives, personnel, and passengers across the rail network.