In modern Railway Systems or Rolling Stock, the Master Controller, also known as the Driver Control Unit or Train Operating Console, is the primary device used to manage acceleration, braking, and direction. These components are critical to train safety and performance, making rigorous testing essential.

We have developed a specialized Master Controller Test Bench, designed for testing a wide range of locomotive control handles, cab control units, and driving/braking consoles with accuracy and ease.

Applications:

• Train OEMs and Master Controller Manufacturers
• Railway equipment maintenance and repair depots
• R&D labs working on new locomotive designs
• Quality control departments validating production units

Deliverables:

• Electrical Control System (Table Top/ Rack mount): Hardware platform to interface with the Master Controller
• Application Software License: Powerful, easy-to-use test automation software

Optional Accessories/ Not included in this Item Code:

• Mating Connectors of Master Controller under Test
  • It is mandatory for testing. And we connect it as per customer’s Master Controller under test. Because different Make Master Controllers have different connectors and pin configurations.
• Laptop or PC

Tests:

• 64 pin Continuity Testing
  • For verifying wiring, switch NO/ NC contacts, and I/O connectivity
• 9-bit Gray Code Inputs
  • 2 Channels
  • Validates rotary handle encoder outputs
• 0-10V Analog Inputs
  • 2 Channels
  • Common in lever-based throttle or braking controls
• 0-20mA Analog Inputs
  • 2 Channels
  • Used in industrial-grade control systems

These tests help ensure that every train cab control device is functioning precisely as required under real operating conditions. It also covers majority of Master Controllers of reputed brands and different variations. If you want to test any Master Controller which do not get covered up with above specifications, please let us know.

How It Works ?

Step 1: Connect the train Master Controller (Device Under Test) to our Test Bench using the standard interface.

Step 2: Launch the application on your laptop, Select appropriate Recipe of your Master Controller and click the Start button.

Step 3: Software will instruct the operator to simulate driving conditions by using handles, brake levers, switches, and reversers.

Step 4: The system monitors each control signal and verifies whether the expected electrical outputs are being generated.

You receive immediate Pass/Fail results for every action, enabling efficient validation of the controller’s behavior.

Real-Time Feedback:

Clear Pass/Fail indication for each functional test step

Live monitoring of Gray code, Analog signal levels, and switch statuses

Easy-to-navigate GUI that helps technicians and engineers stay in control

Other Salient Features:

• Data Logging and Traceability
• Test Recipe Master: Add/ Edit/ Delete Test Recipes.
• Result CSV file direct email facility. No need of Pen drive
• Auto Mode: For Production Use
• Calibration Mode: For Calibration of internal instruments
• Multi-User system with different authorities: Engineering, Quality, Maintenance, Production, Operator.
• System Health Check: For Preventive and Corrective Maintenance
• Industry 4.0 compliant system
• Machine to Machine communication capability
• 21CFR compliant