High-throughput environmental testing for cabin height control valves at WABCO

Company overview

WABCO is a leading global supplier of technologies and services that improve the safety, efficiency, and connectivity of commercial vehicles, specializing in braking, stability, and transmission automation systems for trucks and trailers.

Executive summary

The design and implementation of a custom, multi-valve tester has provided a transformative solution for WABCO, including:

• A massive increase in testing throughput, enabling validation of 16 valves simultaneously.
• Full compliance with stringent OEM requirements for reliability and environmental endurance.
• Elimination of process downtime related to equipment temperature limitations.
• Enhanced flexibility to test multiple product variants and adapt to future needs.
• Delivery of a fully documented, certified, and turnkey testing platform.

Project objectives

WABCO required a solution that would:

• Significantly increase the throughput of their valve testing process.
• Meet the demanding reliability and environmental testing standards set by an OEM within a critical project timeline.
• Perform complex endurance tests in a wide range of temperatures and high humidity.
• Provide a flexible, user-friendly system for testing multiple valve variants.

The challenge

The client’s existing testing equipment was a bottleneck, unable to process the required number of products and failing to meet the reliability levels demanded by the OEM. This insufficiency threatened to delay the project timeline. The process was further hampered by the previous equipment's narrow operational temperature range, which necessitated frequent and time-consuming changeovers. A new, robust solution was needed to conduct high-volume endurance testing across extreme environmental conditions for multiple product variants.

The solution

A high-performance tester was designed and built to execute a complete test sequence on 16 valves simultaneously, with the flexibility to test up to 4 different product variants at the same time. The entire system operates within an environmental chamber, enduring 95% humidity and a temperature range from -40 °C to +100 °C.

To simulate real-world road conditions and prove durability, the tester performs 60 million activations at a frequency of 11 Hz, with precise control over the rotational speed of electric motors and the stroke of pneumatic cylinders. The system is managed by a SIEMENS PLC controller and a simple HMI panel, allowing operators to easily select the correct test sequence for each variant via a step-by-step procedure.

The tester was designed for real-world accuracy, using original vehicle components to simulate the pneumatic system volume and valve mounting. The design is fully compliant with safety directives (including limit switches and current protection) and allows for quick conversion to test other types of valves. The project was delivered as a comprehensive turnkey solution, including on-site installation, configuration support, complete documentation with a user manual, and a final CE certificate.

Key achievements

Massive throughput increase

The device’s ability to test 16 valves at once dramatically increased testing capacity and accelerated the project timeline.

Extreme environment capability

The solution performs reliably in harsh conditions, from -40 °C to +100 °C at 95% humidity, meeting the most rigorous OEM standards.

High-frequency endurance testing

The tester validates component durability by performing up to 60 million cycles at 11 Hz, ensuring products can withstand long-term use.

Enhanced flexibility and usability

The system allows for easy testing of 4 different variants via a user-friendly HMI and is designed for quick changeovers for future products.

Certified turnkey solution

A complete, safe, and fully documented solution was delivered to the customer, including installation, support, and CE certification.