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Dynamometer Test Bench Revamping

Global projects
ClientGlobal projectsYearJanuary, 2023AuthorNick JonesShare
- Case Study -

Dynamometer Brake Test Bench Revamping

Banco prova dinamometrico con motore accoppiato per test meccanici

Issue Identified:

In the railway sector, particularly in train manufacturing, there was a clear need for accurate and efficient testing of brake system components (shoes, calipers, discs, linings) for locomotives and wagons, in compliance with strict technical standards such as UIC FICHE 548.

Main issues included:

  • Lack of a complete system for testing brake behavior under real-world operating conditions

  • Difficulty in real-time data acquisition and management during testing

  • No integrated tools for automated report and graph generation

  • Need for an intuitive user interface for both automatic and manual test control

Solution:

Opus Automazione carried out a full revamping of the dynamometer brake test bench, implementing a highly automated, modular system compliant with regulations.
The solution is divided into three main areas.

Mechanical Structure:

  • Traction motor and simulated flywheel masses

  • Enclosed test cabin for housing the wheel/brake assembly

Hardware and Automation:

  • DC driver for main motor control

  • PLC for test logic management

  • National Instruments cRIO system for data acquisition and real-time force calculations

  • LabView HMI for visualization, SQL database archiving, and automated report generation

Management Software:

  • Real-time status, alarms, and graph display

  • Automatic or manual test execution

  • Creation of test “recipes” and brake acoustic analysis

  • Intuitive interfaces for motor adjustment, test management, and PID configuration

Results Achieved:

  1. Full control and precision regulation of speed and torque on the test bench

  2. Advanced automation, reducing manual errors and enhancing repeatability

  3. Efficient data collection with real-time processing and smart post-processing

  4. Enhanced, intuitive user interface, suitable even for non-specialized operators

  5. Compliance with railway testing standards, ensuring test reliability

  6. Automated report and graph generation, improving traceability and documentation of test results


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