Electro Pneumatic test jig

The brake testing system of a locomotive requires precise pressure control between 3.8 and 5.5 kg/cm2 to ensure reliability over long distances. A loco engine runs lakhs of miles coupled with either a passenger train or freight carrier. Technical blueprint

To achieve this, we utilized I2P converters from SMC controls, known for their accuracy of +/- 1% of full scale. The firmware includes an auto correction algorithm using support vector regression, which reduces system deviation to +/- 0.1% of full scale, keeping pressure variability within +/- 0.1 bar. This was a challenging task to achieve, as it required reducing the accuracy to 1/10th of the component accuracy. The console features a web app hosted by the microcontroller's webserver, with a user-friendly interface suitable for tablets. It allows for multi-tier cascaded control and real-time response visualization. Additionally, it is a cross-platform solution that can be integrated with other terminal-based software using the appropriate URL parameters and values.