D7.2 DAC Level 5 Interoperability Report

This deliverable presents the results of the first interoperability laboratory tests up to Functional Level 5 (FL5) carried out jointly by the four DAC supplier beneficiaries – Dellner, Knorr-Bremse, Voith, Wabtec – within FP5‑TRANS4M‑R. These tests represent the second interoperability campaign performed in laboratory conditions. The previous one was conducted with DAC Functional Level 4 (FL4) in WP 6 within the project and reported in Deliverable D6.2.  Earlier individual component qualification activities for DAC FL5 were documented in D7.1. 

The primary objective of the test campaign was to verify interoperability and functional readiness of DAC Level 5 solutions, including mechanical, pneumatic, electrical, and digital interfaces. Each supplier provided a functional FL5-ready coupler equipped with a simulation box for automated uncoupling, enabling comparable and repeatable testing across all cross‑supplier configurations. 

The tests followed the procedures defined in Deliverable D5.3 and relevant European standards (e.g., EN 16019, EN 60512). Test categories included: 

• Mechanical coupling and decoupling performance 

• Gathering range verification under defined deflection conditions 

• Pneumatic leakage and functional checks 

• Electrical and digital communication tests using the Voith E‑Coupler 

• Actuator performance, including automated uncoupling under braked and unbraked conditions 

The testing confirmed that all four DAC solutions demonstrate FL5 readiness under laboratory conditions, meeting the requirements needed to progress toward train integration and field testing in WP14. The successful outcomes also demonstrate significant progress in the harmonization of mechanical and functional interfaces, achieved through close coordination and standardization efforts within the DAC Core Group. 

The validated test results support Quality Gate 1 (Component Qualification) and provide the basis for upcoming interoperability tests in operational environments, which will be reported in Deliverable D7.3.