Mobile Testing System for Brake Systems

SPANGLER – the Plus in Innovation.

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.