Test Rig for IRAB Brake System / 8–10 kg/cm² · 2,000 LPM / 18 Valve Types · RDSO-Compliant / India

IRAB · PNEUMATIC BRAKE VALVE TEST BENCH

Test Rig for IRAB Brake System, rated to 8–10 kg/cm² & 2,000 LPM.

A comprehensive, automated pneumatic bench for rigorous validation of 18 valve types used in electric-locomotive IRAB (Indian Railway Air Brake) systems. Dual 250 kW compressors, a Siemens PLC safety-interlock system and 24-bit DAQ, driven by bespoke “CCUBTB” software with automatic, manual and calibration test modes.

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Test Rig for IRAB Brake System front console - stainless steel enclosure with digital pressure gauges by Neometrix

Fig · 01 Front control panel · stainless-steel enclosure · digital pressure readouts

Designed and manufactured to:

RDSO UIC EN Standards ISO 8573-1

Supply Pressure

8–10kg/cm²

Flow Capability

2,000LPM

Valve Types

18types

Compressor Power

2×250kW

DAQ Sampling

1kHz/ch

Overview

One rig, eighteen valve types.

Engineered to meet the exacting demands of modern electric locomotive maintenance and R&D, the rig replicates real-world supply pressures, flow rates and temperature variations to validate IRAB valve performance end to end.

Test Rig for IRAB Brake System with stainless steel cabinet and instrumentation rack by Neometrix

Fig · 02 Stainless-steel enclosure with front-panel digital gauges and instrumentation rack

IRAB — the Indian Railway Air Brake system — relies 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, the Neometrix 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. Dual 250 kW compressors hold 8–10 kg/cm² supply pressure at up to 70 CFM (2,000 LPM), with ±0.02 kg/cm² stability.

Eighteen valve types. One automated bench.

A Siemens S7-1200 PLC manages safety interlocks — relief valves, E-stop and watchdog — while a 24-bit DAQ samples at up to 1 kHz per channel, logging graphs and trends to SQL for analysis and one-click PDF reporting through the bespoke “CCUBTB” software.

Architecture

Five systems, one test bench.

Every subsystem of the IRAB test rig is engineered around precise pneumatic control, safe operation and traceable performance data.

Sub · 01

Stainless-Steel Enclosure

Corrosion-resistant frame with roll-out covers and an integrated condensate tray for rapid fault isolation and servicing.

Sub · 02

Air Preparation Unit

5 µm prefilter, 0.01 µm coalescing filter, refrigerated dryer and particulate filter to ISO 8573-1 Class 1.

Sub · 03

PLC & DAQ Rack

Siemens S7-1200 PLC for safety interlocks; 24-bit NI DAQ for high-speed data streaming to the PC workstation.

Sub · 04

Control Console

Industrial touchscreen for local overrides, status LEDs and emergency-stop, alongside front-panel digital pressure gauges.

Sub · 05

PC Workstation

High-performance workstation running “CCUBTB” software, communicating via USB-Ethernet module for recipe control and reporting.

Sub · 06

Dual Compressor Bank

Two 250 kW compressors deliver up to 70 CFM (2,000 LPM) at 8–10 kg/cm² nominal supply pressure.

Operation

Three modes, one workflow.

The CCUBTB software drives every test through a consistent sequence, whether run automatically, manually or in calibration.

Automatic mode

Select a test recipe — valve type, pressure ramp, dwell times.
System purges and pre-pressurizes to the target setpoint.
Executes the actuation sequence, recording pressure curves and leakage.
Auto-generates a pass/fail verdict based on preset tolerances.

Calibration mode

Reference sensors are disconnected for comparison against certified gauges; the software logs new calibration factors automatically.

Manual mode

The technician triggers individual solenoid or manual valve actuations via console toggles, with live pressure readouts for on-the-fly troubleshooting and diagnosis.

Software & 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, with CSV/Excel export.

Image Gallery

The rig, on the factory floor.

Product and internal-assembly views from a delivered Test Rig for IRAB Brake System — console, air preparation and pneumatic manifold detail.

Test Rig for IRAB Brake System front console on-site view by Neometrix

Test Rig for IRAB Brake System nameplate and digital pressure gauge panel by Neometrix

Test Rig for IRAB Brake System full stainless steel enclosure front quarter view by Neometrix

Test Rig for IRAB Brake System internal pneumatic manifold and copper piping by Neometrix

Test Rig for IRAB Brake System front panel gauge cluster close up by Neometrix

Test Rig for IRAB Brake System internal receiver tanks and solenoid valves by Neometrix

Test Rig for IRAB Brake System pneumatic tubing and control wiring detail by Neometrix

Test Rig for IRAB Brake System instrumentation and solenoid valve bank by Neometrix

Test Rig for IRAB Brake System overhead piping and cable routing by Neometrix

Design Drawings

Fabrication references.

Dryer mounting-base and front-panel print drawings for the standard configuration, available as PDF for procurement and technical review.

Test Rig for IRAB Brake System dryer mounting base drawing by Neometrix

Fig · 03 Dryer mounting-base drawing — top, front and isometric views

Test Rig for IRAB Brake System front panel print drawing by Neometrix

Fig · 04 Front-panel print drawing — Panel 1 and Panel 2 layouts

Downloads

Catalog & drawings.

Product catalog and drawing PDFs for the Test Rig for IRAB Brake System, available for procurement and technical review.

Catalog

Test Rig for IRAB Brake System — Product Catalog

PDF

Drawing · General

Test Rig for IRAB Brake System — General Arrangement

PDF

Drawing · Design 1

Test Rig for IRAB Brake System — Dryer Mounting Base

PDF

Drawing · Design 2

Test Rig for IRAB Brake System — Front Panel Drawing

PDF

Specifications

Full technical parameters.

Key system parameters for the standard Neometrix Test Rig for IRAB Brake System configuration.

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
Pressure Stability	±0.02 kg/cm²
Temperature Range	0–48°C ambient
Power Requirement	230 VAC ±10%, 50 Hz, 5 kVA
Footprint (W×D×H)	1.5 m × 0.8 m × 1.8 m
Weight	~650 kg
Noise Level	< 75 dB(A) at 1 m
Compressors	Dual 250 kW units
Air Preparation	5 µm prefilter, 0.01 µm coalescing filter, refrigerated dryer, ISO 8573-1 Class 1
Control	Siemens S7-1200 PLC, industrial touchscreen console
Software	Windows 10 Pro, .NET Framework, SQL Server, “CCUBTB” application
Valve Coverage	18 valve types across all IRAB sub-assemblies

Applications

Where it tests.

From OEM assembly lines to railway academies, the IRAB test rig serves any application requiring reliable, traceable brake-valve validation.

A · 01OEM production quality control inline in locomotive and valve-OEM assembly lines

A · 02Depot maintenance and annual overhauls in railway workshops

A · 03Field commissioning and turnkey installations for new or refurbished locomotives

A · 04Regulatory certification and compliance testing to RDSO, UIC and EN protocols

A · 05Research, development and accelerated life testing of new valve designs

A · 06Training and skill development at technical institutes and railway academies

A · 07Aftermarket support and spare-parts validation against OEM benchmarks

In Depth

The complete technical read.

Engineering narrative for railway maintenance engineers, procurement teams, and QA managers who want the full picture before committing to an installation.

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 — the Indian Railway Air Brake system — relies 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.

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 emergency-stop.
PC workstation: high-performance machine running “CCUBTB” software; communicates via USB-Ethernet module.

Operation modes

Automatic mode:

Select test recipe (valve type, pressure ramp, dwell times).
System purges and pre-pressurizes to target.
Executes actuation sequence, records pressure curves and leakage.
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.

FAQ

Common questions.

Plain-language answers from the engineering team.

Q · 01 What is the Test Rig for IRAB Brake System?

It is an automated pneumatic test bench built by Neometrix Engineering Pvt Ltd, India, for validating 18 valve types used in the Indian Railway Air Brake (IRAB) systems of electric locomotives, covering actuation, leakage, response time and release performance.

Q · 02 What does IRAB stand for?

IRAB stands for Indian Railway Air Brake system, the pneumatic brake network used on Indian Railways electric locomotives that this rig is designed to test and certify.

Q · 03 What supply pressure and flow does the rig deliver?

The rig holds 8–10 kg/cm² nominal supply pressure (max 10.5 kg/cm²) with ±0.02 kg/cm² stability, and delivers up to 70 CFM (2,000 LPM) via dual 250 kW compressors and an ISO 8573-1 Class 1 air-preparation unit.

Q · 04 How many valve types can the rig test?

The rig covers 18 valve types across all IRAB sub-assemblies, including brake valves and safety valves, using parameterized test recipes in the CCUBTB software.

Q · 05 What operating modes does the rig support?

Three modes are available: Automatic (recipe-driven purge, pressurize, actuate and auto pass/fail verdict), Manual (technician-triggered solenoid or valve actuation for troubleshooting), and Calibration (reference-sensor comparison against certified gauges).

Q · 06 What data acquisition and control hardware does it use?

A Siemens S7-1200 PLC manages safety interlocks while a 24-bit DAQ samples at up to 1 kHz per channel, logging pressure and leakage curves to SQL Server and generating one-click PDF reports through the CCUBTB software.

Q · 07 What standards does the test rig support certification against?

The rig executes RDSO, UIC and EN endurance and safety protocols — including rapid charge, slow release and high-temperature cycling — and generates the full data logs and PDF documentation required for type-approval and re-certification.

Q · 08 Who uses this test rig?

It is used by locomotive and valve OEMs for production quality control, railway workshops for depot maintenance and overhauls, field teams for commissioning, R&D labs for accelerated life testing, and technical institutes for training.

Q · 09 Is the rig customizable?

Yes, Neometrix configures the enclosure, valve fixtures, DAQ channel count and CCUBTB test-recipe library to match specific valve families and site certification requirements.

Q · 10 How can I get a quotation for the Test Rig for IRAB Brake System?

You can request a quotation for the Test Rig for IRAB Brake System by contacting Neometrix Engineering Pvt Ltd through https://neometrixgroup.com/products/test-rig-for-IRAB-brake-system or by phone at +91-7777-876-876.

Get a proposal

Tell us your valve-testing
and certification needs.

We configure the enclosure, valve fixtures, DAQ channels and CCUBTB recipe library, and walk through documentation and site requirements with your project team before you commit.

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