Details
The Microprocessor Controlled DV Test Bench is a precision-engineered system designed for testing, analyzing, and validating Distributor Valves (DV) used in railway braking systems. It ensures that railway braking components meet safety, efficiency, and performance standards before being installed in rolling stock. This system is widely used in railway maintenance depots, rolling stock manufacturing plants, research and development facilities, and brake system production units.
The test bench is designed to simulate real-world railway braking conditions by controlling air pressure variations and monitoring braking responses under different scenarios. The test results help identify faults, leaks, sensitivity issues, and response delays in distributor valves before they are deployed in active railway service.
• Advanced Microprocessor Control – Enables high-speed data processing and precision in test execution.
• Fully Automated Testing – Executes predefined test sequences with minimal human intervention.
• Manual Testing Mode (A9 Operated Mode) – Allows manual control via A9 Driver’s Brake and Toggle Switches, simulating real-world railway brake applications.
• Integrated Data Acquisition System (DAQ) – Records, processes, and logs test results with real-time graphical analysis.
• High-Pressure Testing Capability – Operates at 10 Kg/cm2 to match real-world railway braking pressures.
• Adjustable Brake Cylinder Stroke – Customizable settings allow compatibility with different brake cylinder diameters.
• High Flow Rate – 2400 LPM (Liters Per Minute) air supply ensures efficient testing.
• Comprehensive Test Reporting – Generates detailed logs, performance charts, and compliance reports.
• Multi-Mode Operation – Supports automatic and manual test execution.
• User-Friendly GUI Interface – Enables simplified control through an Industrial PC (IPC) with touchscreen support.
• UPS Backup System – Prevents power interruptions, ensuring continuous testing.
Testing Capabilities
The DV Test Bench performs a wide range of functional and performance tests to ensure the correct operation of distributor valves. These tests help validate braking efficiency, pressure control, leak prevention, and emergency braking functionality.
1. Charging and Leakage Tests
• Charging Time Test – Measures the time required to charge Auxiliary Reservoir (AR) and Control Reservoir (CR). Ensures that the braking system achieves full pressure in the expected time frame.
• Leakage Test – Detects potential air leaks in the system that could compromise braking performance and cause safety failures.
2. Brake Application and Release Tests
• Brake Application Time Test – Determines the time taken for the brake cylinder to pressurize and engage the braking system.
• Full Service Application – Simulates normal railway braking conditions.
• Emergency Application – Simulates emergency braking conditions requiring instant pressure buildup.
• Brake Releasing Time Test – Measures how fast the brakes release after application.
• Full Service Brake Release – Evaluates the braking system’s responsiveness under normal conditions.
• Emergency Brake Release – Ensures the emergency brakes disengage properly once the train is safe to move.
• Maximum Brake Cylinder Pressure Test – Verifies whether the distributor valve can generate the required brake pressure under both full-service and emergency braking conditions.
3. Sensitivity and Control Response Tests
• Sensitivity Test – Measures how quickly and accurately the distributor valve responds to minor pressure fluctuations.
• Insensitivity Test – Ensures the braking system does not react unnecessarily to insignificant pressure changes, preventing false brake applications.
• Graduated Application Test – Evaluates the distributor valve’s ability to apply braking force in increments, ensuring smooth and controlled braking.
• Graduated Release Test – Ensures the distributor valve can gradually release braking force, preventing sudden jerks or instability.
• Re-feeding Test – Verifies if the valve can restore pressure levels effectively to maintain braking control.
• Availability of Brake Pipe Pressure – Ensures that the brake pipe maintains the necessary pressure levels at all times.
• Overcharge Protection Test – Assesses whether the system can prevent over-pressurization, which could damage braking components.
• Quick Release Valve Test – Tests how efficiently the system discharges excess pressure when needed.
System Specifications
• Working Medium – Compressed Air
• Maximum Pressure Rating – 10 Kg/cm2
• Air Supply Pressure Range – 8-10 Kg/cm2
• Flow Rate – 2400 LPM (Liters Per Minute)
• Temperature Range – Ambient Conditions
• Brake Cylinder Compatibility – Supports adjustable stroke lengths for different brake cylinder sizes.
• Compliance – RDSO-Approved Brake Cylinder & Air Reservoir
Operating Modes
The system features dual working modes, allowing flexibility for various testing scenarios.
1. Automatic Mode
• Tests are executed automatically using a predefined test sequence.
• Operators can also select individual tests manually when needed.
• Ensures consistency, repeatability, and precision in test results.
2. Manual (A9 Operated) Mode
• The operator manually controls the tests using an A9 Driver’s Brake and Toggle Switches.
• Allows real-world simulation of braking actions under controlled conditions.
• Useful for training, troubleshooting, and detailed component analysis.
Mode Selection
• Operators can switch between Automatic Mode and A9 Operating Mode via a Mode Selector Switch.
Data Acquisition & Reporting System (DAQ)
• Real-time Data Monitoring – Captures and logs pressure levels, timing data, and brake response parameters.
• Graphical Analysis – Provides visual representations of test performance, including pressure curves and response time charts.
• Industrial PC (IPC) with GUI – Offers touchscreen and keyboard operation for seamless test control.
• Automated Report Generation – Creates detailed test logs, compliance reports, and maintenance documentation.
• Printer Integration – Enables on-demand printing of test results for record-keeping and analysis.
• UPS Backup – Ensures uninterrupted operation, preventing data loss and system downtime.
Additional Accessories
• DV Overhauling Table – Dedicated workbench for maintenance, repair, and reassembly of distributor valves.
• DV Mounting & Dismantling Adjustable Trolley – Assists in safe handling and transportation of heavy components, reducing manual labor.
Applications & Industry Use
• Railway Maintenance & Testing Facilities – Ensures safety compliance and operational reliability.
• Railway Workshops & Depots – Used for fault detection, preventive maintenance, and brake system validation.
• Brake System Manufacturers – Supports quality control and performance validation.
• Rolling Stock Manufacturers – Enables pre-installation testing for braking systems.
• Research & Development (R&D) Centers – Supports innovation and performance testing in railway braking technology.