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.
The comprehensive modernization of legacy test equipment delivered a future-proof solution for WABCO, with key benefits including:
As part of a production transfer between plants, WABCO needed to:
The project's primary challenge was the modernization of legacy equipment that completely lacked technical documentation and CAD models. The existing test sequence, written in an outdated Visual Basic program, had to be reverse-engineered from the code and the existing electrical system. The system required a complete overhaul to introduce modern control systems, integrate with numerous existing components, and communicate with a central traceability system, all while adapting the physical hardware for new product variants.
Two vacuum pump testers were comprehensively modernized. The project began by recreating the entire test sequence and reverse-engineering the existing test sockets to support a new product variant. A modern control system, based on an NI card and LabView software, was implemented to provide precise control over critical parameters like rotation speed and pressure.
The testers' functionality was significantly expanded to meet Industry 4.0 standards. This included adding new sensors for measuring motor speed and atmospheric pressure, and integrating a label printer. The process was automated with a pump detection sensor that triggers automatic label printing and KEYENCE optical sensors that verify the label's presence and correct positioning. Communication with a central traceability system was established to register all process parameters for each unit tested.
The hydraulic supply system was upgraded with intelligent software solutions to optimize pressure usage, reducing energy consumption. A separate, additional station for leakage testing was also designed and built. The project concluded with a comprehensive installation, configuration support, the creation of full documentation (including risk analysis), and the issuance of a CE certificate.
Legacy equipment was successfully transformed to meet modern standards, including full communication with a central traceability system for data-driven manufacturing.
A fully functional and documented solution was created from undocumented legacy equipment, preserving initial investments while upgrading capabilities.
The introduction of advanced sensors and a LabView-based control system enabled precise process control and automated steps like label printing and verification.
The hydraulic system was successfully optimized to reduce temperature increase and lower overall electricity consumption during operation.
A complete solution was delivered, including installation, configuration, a new leakage testing station, full technical documentation, and CE certification.
