Details

1. Introduction
The E-70 Brake Equipment Test Rig is a state-of-the-art, fully automated test facility designed specifically for evaluating, validating, and certifying the full spectrum of E-70 brake equipment used across locomotive fleets. Developed in full conformity with COFMOW (Central Organisation for Modernisation of Workshops) and Indian Railways standards, this rig ensures exhaustive testing under precisely controlled hydraulic and pneumatic parameters. In today’s railway sector, where safety margins are tightly regulated and failure tolerances are nearly zero, this rig ensures absolute reliability for mission-critical braking systems.

2. Key Features
Precision Automation:
 • Fully automated test sequences for leakage, functional, endurance, and dynamic response testing.
 • User-definable test protocols for new product development.
 • High-speed DAQ system (≥1 kHz) for real-time data.
 • Graphical trend plots with auto-generated pass/fail reports.

Advanced Pneumatic & Hydraulic Subsystems:
 • Hydraulic pressure up to 1,060 kg/cm² (15,000 psi).
 • Multiple independent hydraulic zones.
 • Twin-tower refrigerated air dryer (<5°C dew point).
 • Pneumatic reservoirs (240L & 450L) with auto-drains.

High-Fidelity Measurement & Calibration:
 • 22 analog + 2 digital pressure gauges.
 • Calibration traceable to NIST/NABL.
 • High-resolution transducers for leak detection.

Fail-Safe Safety Systems:
 • Auto-locking clamps during power failure.
 • Emergency stop stations.
 • Interlocked electric/hydraulic/pneumatic circuits.
 • Compliant with IEC 60204-1 safety standards.

Operator-Friendly Design:
 • Ergonomic control console with touchscreen HMI.
 • Multi-language PLC interface.
 • Quick-change test fixtures.
 • Quiet operation (≤80 dB(A)).

Long-Term Reliability:
 • Stress-relieved cast iron structure.
 • Centralized lubrication with indicators.
 • Long MTBF components and design.

3. Application
 1. New Product Development & R&D
  • Performance benchmarking of newly designed E-70 brake valves.
  • Endurance cycling and pressure response tests to validate design changes.
  • Correlating real-world test data with FEA (Finite Element Analysis) simulations.

 2. Production Quality Control
  • Inline testing of manufactured brake components before dispatch.
  • Automated comparison with acceptance criteria as per Indian Railways and international standards.

 3. Depot Maintenance & Repair Verification
  • Post-repair testing of overhauled brake assemblies.
  • Leak integrity checks on seals, diaphragms, and piston chambers.
  • Ensures repair work meets original factory standards and reduces field failures.

 4. Training & Skill Development
  • Hands-on experience for maintenance engineers and technical staff.
  • Simulated faults for troubleshooting training.
  • Certification-based evaluation on real hardware.

 5. Third-Party Certification & Compliance
  • Supports compliance with AAR, UIC, EN, ISO testing protocols.
  • Suitable for audit-based verifications and certifications.

4. Technical Specifications

  
Parameter
Specification
  
Hydraulic Pressure
0–1,060 kg/cm², ±0.5% regulation
  
Hydraulic Flow
Up to 50 L/min, multi-zone control
  
Pneumatic Pressure
0–10 kg/cm², dew point ≤ 5°C
  
Reservoir Capacities
Pneumatic: 240L & 450L; Hydraulic: 200L
  
DAQ System
≥ 1,000 samples/sec, 24-bit, 16+ channels
  
Control Interface
Siemens/Allen-Bradley PLC, 15” HMI
  
Power Supply
415V ±10%, 3-phase, stabilized
  
Motors
VFD-controlled, up to 5 kW
  
Noise Level
≤ 80 dB(A), ISO 3746
  
Safety Standards
IEC 60204-1, IS 325, IS 1248, IS 375, IS 6875
  
Operating Conditions
5°C to 40°C; indoor use
  
Data Connectivity
OPC-UA, Ethernet, remote monitoring


5. Bill of Materials (Highlights)

  
Item
Description
  
1
Hydraulic Power Pack (pump, tank, valves)
  
2
Pneumatic Air Dryer Unit (twin-tower)
  
3
Pneumatic Reservoir Tanks (240L, 450L)
  
4
Hydraulic Manifolds (RBTR series)
  
5
Pressure Gauges (Analog & Digital)
  
6
Centralized Lubrication Unit
  
7
PLC Controller + HMI Touchscreen
  
8
DAQ Acquisition Modules
  
9
Electrical Control Panels (interlocked)
  
10
VFD Drives with Motors (IEC-rated)
  
11
Emergency Stop Network
  
12
Cables, Hydraulic & Pneumatic Tubing
  
13
Quick Change Test Fixtures
  
14
Calibration & Test Adaptors
  
15
Initial Spare Parts & Consumables


6. Conclusion
The E-70 Brake Equipment Test Rig stands at the frontier of modern railway testing infrastructure. More than just a test bench, it serves as a comprehensive validation platform covering the entire lifecycle of E-70 brake components — from design and development to production, maintenance, and training. Built with rugged durability, precision systems, and ergonomic design, it’s an integrated solution for railway brake testing excellence.