As part of our ongoing collaboration with Knorr-Bremse, the global market leader in brake systems for rail and commercial vehicles, we are introducing a pioneering project: the development of a mobile testing system for brake systems. This innovation enables service technicians to carry out all maintenance work, tests, trial operations, and software updates directly on the brake equipment in trains – without having to use the train’s infrastructure or dismantle the devices from the vehicle.

To meet the demands of service personnel, Spangler was commissioned to design a mobile testing system for maintenance and testing purposes. It will significantly expand maintenance and testing possibilities throughout the entire life cycle.

Project Development and Implementation

Our task was to design and manage the integration of all necessary electrical components into a space-saving case solution that meets aesthetic and ergonomic standards and passes all testing and approval procedures. All electrical components – including power supply, protective devices, and decentralized peripherals – were efficiently and compactly housed in a protective case.

Technical Excellence

The device was tested under the most demanding conditions, including climate tests with dry and humid heat, sudden temperature changes, condensation, and precipitation, as well as mechanical tests for oscillation, vibration, and shock. In addition to electromagnetic compatibility (EMC), it complies not only with European but also international standards.

The Core of the Mobile Testing System

Remarkably, the control logic of the mobile testing system is in the service technician’s laptop, which is connected via USB-C and RJ45. Our development work focused on electrical design, including circuit diagram creation, and was driven forward through regular, creative workshops in collaboration with Knorr-Bremse.

Current Status and Outlook

After providing the documentation, the prototype phase has now begun, including a mock-up, two prototypes, and an initial production run (0-series). Project support will continue for several more months, with ongoing adjustments and improvements.

In the dynamic world of civil engineering, we’ve set new standards with our latest project for Implenia, a company specializing in foundation engineering. Our custom solutions have significantly improved on-site efficiency while also demonstrating our ability to precisely meet our customers’ needs.

Mobile, Innovative Solutions in Use Across Europe

The key challenge was to design a mobile system that can be easily adapted to various construction sites throughout Europe. The core of this innovation are 30 frequency-controlled pumps integrated into a specially adapted sea container. This system enables processes that were previously carried out manually to now be executed fully automatically and much faster.

Efficient Ground Stabilization in Foundation Engineering

The system is used in specialized foundation engineering work to create a stable base by forming a sealing layer directly in the ground. By injecting a special material into the pore space, water permeability is almost entirely reduced, allowing the construction of buildings with basements – such as school buildings – even in groundwater areas.

A Quantum Leap in Process Optimization

Implenia has successfully transitioned from manual to automated control systems – with significantly accelerated workflows as a result. The fully automated control and documentation of each step is a first, made possible by our software and hardware solutions.

Technical Sophistication and Customized Software Development

The control concept developed by Spangler includes not only the hardware components but also tailor-made software that integrates handheld scanners and barcodes for clear identification and documentation of work processes. This solution provides seamless documentation that is transmitted directly from the construction field to the central system.

Forward-Thinking Concepts with Wi-Fi and Mobile Applications

Special attention was paid to optimized Wi-Fi coverage, ensuring seamless network access across the entire construction field. In addition, an Android app was developed, allowing technicians to work mobile and efficiently—completely independent of stationary systems.

Continuous Optimization

Through the successful implementation of this project, we are laying the foundation for ongoing optimization and flexible adaptation to future requirements. Our role as a full-service provider for both hardware and software enables us to respond flexibly to our customers’ needs and consistently deliver tailored solutions.

For BHS-Sonthofen, a specialist in recycling, construction materials, and process technology solutions, we developed a modern control solution for a vertical dryer (an industrial drying system used for drying bulk materials or pasty substances, e.g., in the food, chemical, or pharmaceutical industry), which stands out for its exceptional efficiency and adaptability.

Advanced Control for Maximum Efficiency

The control system we designed and built consists of two cabinet sections. The core component is a frequency converter with a power rating of 90 kW, which drives the mixing spirals in the vertical dryer. This frequency converter plays a key role in the high efficiency of the drying process, as it enables precise control of the mixing motions while also saving energy.

Since the system operates in a potentially explosive (Ex) environment, we met strict safety requirements. The control cabinet itself is located outside the Ex area, while the locally installed operator panels comply with the standards for Gas Zone 1 and Dust Zone 21. This means the specially manufactured stainless steel operator panels are designed to provide maximum protection in the event of an explosive atmosphere. The special enclosures for this project were supplied by explosion protection expert Exepd to meet the high safety demands. The local operator interface allows specific process requirements to be addressed directly during operation, ensuring a high level of safety and process control.

Adaptable Automation for the Process Technology Market

The dryer itself is designed to efficiently dry various media while ensuring uniform temperature distribution and consistent moisture levels. With its double-walled, conical containers and a central agitator, the material is continuously mixed to allow even heating and drying.

This automation solution enhances process stability and reduces drying times – resulting in a significant increase in production capacity for the end customer.

We built the switch and control system for an innovative surf facility for our customer. The successful completion of the project once again demonstrated our ability to meet the specific requirements of the U.S. market. Located in Dallas, Texas, the facility combines leisure and athletic activity in one. With twelve pumps, each rated at 68 kW, it creates a powerful and authentic wave that delivers an especially natural surfing experience.

A Project Full of Passion and Technical Highlights

In addition to the technical complexity, the control cabinets were built according to the fundamental UL standards of UL508A and subsequently certified. This certificate confirms that our specially trained UL staff meet the high demands for safety and quality, and it qualifies us to carry out inspections and approvals through UL Germany. The diversity of industries and projects provides our employees with variety and opportunities for personal and professional development.

By using E-Plan P8, we were able to plan efficiently, reduce lead times, and ensure high implementation precision – thanks to optimized processes and close collaboration among all project stakeholders.

Certified and Experienced in North American Plant Engineering

Spangler has the necessary expertise and experience to meet the high standards of current regulations and build systems for the North American market. As one of the few German manufacturers, we hold the relevant certification and possess the required technical know-how.