• Validation of rail coach shells, metro cars, and EMU/DMU bodies for water ingress. • Testing of roof seams, side panels, door and window assemblies, HVAC ducts, and underframe seals. • Quality-assurance facilities at coach manufacturing plants, maintenance depots, and R&D centers. • Applicable to steel, aluminium, or composite coach designs. • Adaptable for aerospace, defence-vehicle, or automotive body testing where rain simulation is required.
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Introduction The Water Leak Testing System designed and manufactured by Neometrix Defence Limited is a state-of-the-art, full-scale facility developed to rigorously evaluate the watertightness of railway coaches and rolling-stock car bodies under simulated heavy-rainfall conditions. Modern rail vehicles are built for diverse climates — from arid zones to monsoon-prone regions — and are exposed to driving rain, crosswinds, temperature variation, and prolonged humidity. Even a small leak can compromise passenger safety, electrical systems, and interior furnishings. The Neometrix system replicates these demanding environmental conditions within a controlled chamber, ensuring that every coach structure, weld, and seal achieves complete waterproof integrity before it leaves the manufacturing or overhaul line. Constructed from marine-grade stainless steel and engineered for precision, the facility reproduces the impact, flow distribution, and kinetic energy of natural rainfall through a calibrated network of high-velocity nozzles. The result is a scientifically repeatable, industrial-scale rain simulation, enabling manufacturers to identify micro-leakages, structural weaknesses, or improper sealing in roof joints, window frames, vestibule doors, and HVAC ducts. Beyond mere compliance testing, this machine serves as a quality-assurance benchmark— verifying mechanical craftsmanship, confirming assembly accuracy, and validating long-term service reliability of every rolling-stock vehicle it tests. System Overview The Water Leak Testing System is a closed-loop, stainless-steel chamber designed to house full-length rail coaches, both Standard-Gauge (1,435 mm) and Broad-Gauge (1,676 mm). Measuring approximately 25 m in length, 5 m in width, and 6 m in height, the test bay provides ample clearance around the coach for unhindered water circulation and operator access. Inside this chamber is a modular spray gantry assembly comprising 21 downtake rows, each fitted with 12 precision nozzles, resulting in a total of 252 high-performance spray outlets. These nozzles are arranged to cover the roof, sides, and under-chassis uniformly, ensuring 360° rain exposure across every structural contour. The test sequence is powered by a dual-pump water-circulation system capable of maintaining 3 bar operating pressure and flow delivery exceeding 980 L/min, generating an authentic rainfall velocity of approximately 15.3 m/s. This mimics natural precipitation intensity exceeding 150 mm/hour — enough to expose even minute defects in weld seams or sealing gaskets. Ambient performance remains stable between 5 °C and 50 °C with up to 98 % relative humidity, allowing testing under a wide spectrum of climatic conditions. All control functions — including pump activation, flow rate adjustment, safety interlocks, and real-time monitoring — are centralized through an IP-rated electrical control panel with analog and digital indicators for simplified operator supervision. Construction and Materials Neometrix places strong emphasis on durability, corrosion resistance, and ease of maintenance. The structural framework and critical wetted components are fabricatedentirely from AISI 304 stainless steel, ensuring long life and zero contamination. Structural Elements • Frame Assembly: Heavy-duty SS-304 rectangular pipes (100 × 50 × 3 mm) and SS angles (50 × 50 × 3 mm) form the load-bearing skeleton of the test bay. • Base Plates: 20 mm-thick stainless-steel mounting plates secure the chamber and gantry to the foundation, designed to absorb vibration and hydraulic impulses. • Enclosure Panels: 4 mm translucent polycarbonate sheets enclose the test chamber, offering high impact strength, UV protection, and visibility for observers. • Platform Walkway: Dual-side inspection platforms (25 m × 1 m each) made of 5 mm galvanized chequered plate provide safe access for technicians during inspection and maintenance. • Drainage Floor: The floor is built with a 1 % gradient slope that channels water efficiently toward the collection sump, preventing stagnation or splash-back. Surface Protection All metallic items exposed to moisture are pickled and passivated to enhance surface finish and reduce corrosion initiation. Auxiliary fixtures and brackets are coated with industrial-grade epoxy paint for extended environmental protection. Hydraulic and Pneumatic Subsystems The system uses an integrated network of headers, branch lines, and flexible connectors to distribute water evenly across all 21 downtake rows.
