The BCU Tester enables off train troubleshooting of a BCU rack pair (TC & MC), allowing any faults to be validated to the card level, eliminating the need to send entire BCU racks to the OEM for investigation and repair.

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The design goal was to allow static and dynamic BCU functionality testing. Pneumatic circuits were electrically modelled eliminating the need for compressed air. To achieve this, input and output signals were electronically simulated. The following simulator circuits were developed:

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• Master Controller

• PWM Encoder

• EBC5 (Electronic Brake Control Manifold)

• Speed Sensors

• Dynamic Brake (Traction Braking Effort)

• Air Reservoirs and Pressure Transducers

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The BCU Test Rack provides a number of testing scenarios:

 

• Static Testing – to confirm that specific inputs drive correct outputs. e.g. correct passenger loads, Brake Pipe Pressure (BCP) and Revert to Auto (SACOV activation)

• Dynamic Testing – to validate speed sensor inputs, locked axle alerts and activation of the speed relays (0km/h, 5km/h & 70km/h)

• Dynamic Braking Tests – to validate BCP changes in response to changes in the braking effort achieved by the dynamic brakes, as well as dump valve activation when a slide is detected.