Custom Hydraulic Brake System for Highrail Vehicles

Project Overview

A leading OEM specialising in rail vehicle systems approached OMFB Pacific to design a compact, dual-function hydraulic braking solution for a highrail traction platform. The requirement was to integrate both service and parking brake control into a single system, engineered for space-limited installation and performance under harsh rail operating conditions.

The solution needed to provide:

• Real-time proportional pressure control

• Redundant operation in the event of electrical failure

• Rail-compliant system reliability and safety

• Optimised fluid pathways for efficient flow and minimal pressure loss

• A compact design suitable for under-chassis mounting

Engineering Solution

OMFB Pacific delivered a fully integrated hydraulic braking control system, combining a custom 24VDC hydraulic power pack, precision pressure transducers, and a dedicated manifold assembly.

Key components supplied:

• 24VDC Hydraulic Power Pack – Compact and robust with built-in filtration to maintain clean fluid flow across brake circuits.

• OMFB Pressure Transducers – Provide real-time system feedback for proportional pressure control.

• Custom Manifold Block – Designed to exact specifications to manage pressure and flow for both braking functions.

• Proportional Regulation Circuitry – Enables smooth and adaptive brake modulation under varying loads and conditions.

• Manual Emergency Handpump – Independent of the electrical system, offering a fail-safe backup for parking brake activation.

System Performance

Closed-Loop Precision Control
Feedback from OMFB pressure transducers allows real-time adjustment of hydraulic pressure across both service and parking brake lines, supporting consistent braking response in dynamic operating conditions.

Optimised Flow Architecture
The manifold was developed using flow simulation techniques to reduce pressure loss and eliminate the risk of cavitation during high-load braking events.

Fail-Safe Redundancy
A manual handpump provides full braking capability in the event of power failure, ensuring operational safety in line with railway compliance standards.

Compact Integration
The system footprint was minimised to ensure seamless fitment within the vehicle’s existing chassis space, removing the need for structural modifications.

Outcome & Client Benefits

• Enhanced Safety – Proportional hydraulic braking improves traction and reduces wear on wheel systems.

• Reduced Installation Time – The system is delivered as a pre-tested, ready-to-install kit with minimal integration required.

• Compliance Assurance – Engineered to meet stringent safety and redundancy requirements in rail applications.

• Extended Service Life – High-grade filtration and pressure control reduces component fatigue and supports long-term system reliability.

Why OMFB Pacific

With over three decades of experience in mobile hydraulic systems, OMFB Pacific partners with OEMs to deliver complete control solutions for specialty and transport applications. Our in-house engineering team develops vehicle-specific kits that prioritise safety, reliability, and ease of installation, supported locally throughout Australia and the Asia Pacific.

Need Custom Hydraulic Solutions for Rail or Specialty Vehicles?

Contact OMFB Pacific to discuss your application requirements.

We provide tailored, reliable, and compliant hydraulic systems engineered for performance in demanding conditions.