Functional tester for air preparation 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 development of a custom functional tester has provided a key validation tool for WABCO, with significant benefits including:

• The creation of a testing stand that accurately simulates real-world pneumatic systems.
• A cost-effective final solution achieved through strategic and diligent component selection.
• Precise control and monitoring of the testing environment via an advanced operator interface.
• A flexible and ergonomic construction tailored to the specific requirements of the device.

Project objectives

WABCO required a solution to:

• Build a functional testing stand for a valve responsible for air preparation in trucks.
• Ensure the tester accurately maps the actual pneumatic system found in a vehicle.
• Enable detailed analysis of valve operation under conditions that replicate the end-customer application.
• Incorporate a complex system of 60 pneumatically operated valves into the design.

The challenge

The primary challenge was to design and construct a complex pneumatic system that could precisely simulate the operating conditions of a truck's air preparation system. This involved orchestrating 60 pneumatically operated executive valves to function as a cohesive unit. The solution needed to be cost-effective without compromising technical specifications and required robust, accurate control over operating pressures as high as 20 bar.

The solution

A functional testing stand was engineered to replicate the real-world pneumatic environment for the air preparation valve. The core of the stand is a pneumatic system of 60 executive valves, which are pneumatically operated via valve terminals. The system operates at a pressure of up to 20 bar, with a control pressure of 6 bar.

To achieve a cost-effective design, a series of tests was performed on various commercially available valves. The components that best met the client's specification for performance, price, and delivery time were chosen, which significantly reduced the final cost of the tester.

The entire assembly was built on an adjustable ITEM workbench, which was extended and customized to meet the specific requirements of the device. The necessary electrical components were housed in a dedicated electrical box, with additional measuring tower modules placed in a rack. Pressure sensors are integrated throughout the system to allow for accurate control. The measuring system interface is operated via a control unit equipped with both a touch screen monitor and an LCD monitor.

Key achievements

Real-world system simulation

The stand successfully replicates the actual pneumatic system of a truck, allowing for highly accurate functional testing and analysis.

Cost-optimized design

Strategic testing and selection of commercial valves resulted in a high-performance solution that met budgetary requirements without sacrificing quality.

Precise process control

The integration of pressure sensors and a modern control unit allows for the accurate monitoring and control of the testing environment at pressures up to 20 bar.

Ergonomic and modular construction

Utilizing an adjustable ITEM workbench provides a flexible, organized, and ergonomic platform for conducting complex testing procedures.