Projects

Train Software Integration Facility

The Technobility team were instrumental in the design and build of a Software Integration Facility (SIF) for the Sydney Growth Trains project. The SIF was designed for off train software development, integration testing and preliminary verification to mitigate project schedule risks.

The SIF consists of 8-cars of electronic Train Information System (eTIS) equipment, two drivers and guards work stations, which simulate the train cabs, as well as communications and surveillance equipment such as internal and external destination indicators, advertising screens, speakers and CCTV cameras. Our modular design replicated the on-train installation where practical, using high quality interconnecting cables to ensure robustness and reliability.

To maximise efficiency, we built the SIF at our premises in Silverwater before relocating the equipment to Downers’ facility in North Ryde. On completion of integration testing this equipment will be relocated to Auburn Maintenance Facility to support through life maintenance activities.

Battery Equalisation Chargers

The Technobility team successfully delivered on a contract by Sydney Trains to design and modify a number of Oscar Battery Chargers and supply associated connection harnesses and test equipment. The upgraded chargers were designed to meet Sydney Trains specifications and subjected to rigorous type testing, both on and off train, to confirm equipment performance.

The connection harnesses were designed using rail grade materials, such as PMA conduct and mil-spec Connectors, to ensure equipment reliability and safety within a depot environment.

The test boxes were mounted within Pelican cases ensuring portability, while offering equipment protection.

PWM Encoder Tester

A PWM Encoder tester was developed to test pulse width modulated signals generated by the position of the master controller power brake handle.

The tester contains an integrated power supply and oscilloscope for capturing the PWM signal. Train side signal simulation for ATP (automatic train protection), coupler detection, cab on and master controllers were provided to ensure testing of all inputs and output signals. Train line resistive, capacitive and inductive loads were simulated to provide the load of the train wiring, brake control units and traction modules.

Two PWM Encoders can be tested simultaneously, or independently, forming a head and tail combination. The head and tail can be reversed easily by switching between drivers cabs.

An additional trigger feature was also built in to capture the event of dropped pulses without having to stand over the unit. This allows for non present or over night testing, ensuring spurious PWM signal events are captured.

Electronic Brake Test System

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.

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:

Master Controller
PWM Encoder
EBC5 (Electronic Brake Control Manifold)
Speed Sensors
Dynamic Brake (Traction Braking Effort)
Air Reservoirs and Pressure Transducers

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.

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Pool Gate Component Life Cycle Tester

Technobility was contracted by SafeTech to design and build a pool gate lifecycle test rig to validate their pool gate hinges and magnetic latches in accordance with applicable Australian Standards.

Our design proposal incorporated industrial control system with in house development of the software that provided control, recording and safety provisions.

Prior to the final handover, the test rig had completed in excess of 200,000 cycle operations.