Application Stories: Testing Trains

Biodata produce an extensive range of testing solutions for trains, and design individual systems for specific applications. We test, calibrate and repair equipment, including:

Speedometer | Lucifer Valve | HOD | LFV Valve | Pressure Governor | Telephone Handsets | Air Conditioning | Saloon Temperature Controller | Air Dryer | Microwaves and Ice Makers

See also: Rigorous Safety Testing of New Trains and Wire Proving

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Speedometer Testing

We provide an apparatus for the bench testing of the Pendolino speedometer. This together with a set of software enables the complete testing of the speedometer.

We also provide a system for the routine calibration of speedometers. Six on-train sensors are driven by magnetic fields which simulate rotating wheels. A computer program sets these to the correct frequency for any desired speed. This program can compensate for changes in wheel diameter.

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Lucifer Test Rig

The Lucifer Valve produces a defined pressure in response to an electrical control signal. We offer a pneumatic system for testing these valves.

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HOD Test Rig

This pneumatic system tests a cylinder style actuator.

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LFV Valve Test Rig

The LFV Valve is a pneumatic valve which controls the inflation of train air bags so as to maintain constant ride height.

We sell a computer controlled pneumatic system to test these units. It is based around a mechanical test fixture which allows accurate setting and measurement of valve openings.

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Pressure Governor Test Rig

The Governor Test Set is a pneumatic test rig for the testing and adjustment of a pressure governor valve. It comprises:

• A wall mounted box
• Pressure input connection for pressure in excess of 10 bar
• 4 litre reservoir
• Panel mounted push buttons for fast and slow filling and emptying of the reservoir
• Pressure sensor for the reservoir pressure
• Panel mounted display of this pressure and the state of the Governor contacts
• Connection of the reservoir to the Governor
• Pneumatic conector to allow a Druck meter to monitor the reservoir pressure for calibration purposes
• Test records show the results of the test and the exact switch points of the Governor

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Telephone Test Set

We supply test systems for testing intercom telephone handsets.

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Testing Air Conditioning

HVAC Logger
Biodata offer a portable logging system for recording air flow and coach temperatures. This uses Windmill software for the testing and long term logging of the HVAC both in a test facility and on trains. Graphical displays show values and states of bodyside heaters, roof units and so on. Tests are automated and include report generation.

London Tube Trains
The FPC4 is an air conditioning controller used on London tube trains. We have designed a test arrangement with associated software and can test, diagnose faults and repair these units.

Pendolino Trains
The air conditioning computer of the Pendolino comprises a set of PC104 modules (circuit boards). We designed a set of test fixtures to simulate train inputs and outputs. These in conjunction with software enables the test and repair of the PC104 modules.

Cusac Test Set
The Cusac is a large rack of electrical equipment used for air conditioning control. We provide test equipment and repair of these units.

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Testing the Saloon Temperature Controller

Heating equipment ensures a constant and acceptable temperature in the passenger saloons of each vehicle during periods of cold weather. The saloon temperature control unit monitors the saloon temperatures and controls the heaters. We provide a test system for the temperature controller board, and can repair these boards.

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Air Dryer Testing

Our Air Dryer Testing System can be supplied either as a wall mounted box or as a portable unit.

Wall-Mounted Unit

• Wall-mounted metal box measuring 150 mm x 150 mm
• Mains inlet to 24 V Power supply
• 1 Switch to select either inlet A or inlet B
• 2 Switches to independently control Outlets A and B
• LEDs to display the switch states
• 2 m connection loom to the 4 solenoids
• Terminates in a single connector at the box for easy replacement

Portable Unit

• Metal box measuring 150 mm x 150 mm
• 7 LEDs displaying the voltage on the 7 monitored solenoids
• 7 LEDs displaying the current on the 7 monitored solenoids
• 7 connection leads each 2 m long terminating in a male/female pair to intercept the train signals
• Leads strapped into 3 groups: 3 drains, 2 inlets, 2 outlets
• All fitting in a plastic carry box measuring 300 mm x 400 mm x 245 mm

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Keeping Settings on Microwaves and Ice Makers

Appliances on electric trains, like microwave ovens and ice makers, will lose power when a train passes through a neutral section. In normal use this would mean that the appliances re-set themselves and lose where they were in the cooking or ice-making process.

To solve this we supply power loss devices which can be easily fitted to appliances to ensure that they keep their timings during the power loss.

Ice Maker Power Backup
Our unit maintains the power supply of the ice maker control card during mains failure of up to 45 seconds. This prevents the ice maker restarting its freezing cycle.

The unit comprises a PP3 size rechargeable battery with an output to supply the necessary power. It is housed in a plastic box and connects to the ice maker control board.

When the iced maker is powered, the battery is trickle charged. On power fail it supports the power supply for around 45 seconds. It then switches off to prevent the battery being discharged which would otherwise occur in a few hours.