Situation

Every project begins with identifying the problem. Here the client requested an improvement of the existing tool:

The operator mentionned a lack of ergonomics, the safety was not as per norm and the mechanical concept must be improved to increase tool lifetime.

Top priority: improve safety and ergonomics
Second priority: increase tool lifetime

Concept

During this phase deliverables are agreed. A concept is designed to help the user understand our ideas and ensure we meet the requirements via dialogue.

Teamwork and priority oriented proposals are key to a good concept.

The features of this tool will focus on improving the handling with a ring that holds the hydraulic cylinders in position. This concept will improve ergonomics and permit a user friendly handling.

We choose a spherical plain thrust bearing to be able to resist to the hydraulic cylinder high loads and permit a frictionless rotation of the tightening nut. This new mechanical concept will increase the tool lifetime.

Prototype

Here the experience of the mechanical engineer is key. 

Manufacturing techniques, assembly and manufacturing drawings, as well as communication with selected suppliers are essential.

After assembling the prototype, a test in real time conditions is organised with the operator's team.

Proof of concept

Testing a tool in real time conditions includes operators, working processes and environmental factors.

Prioritised deliverables such as safety, ergonomics and mechanical concept are tested. 

If any issues requiring a second prototype are discovered, we continue testing before placing the full order.

The proof of concept is achieved when a safe mechanical concept is proven, and the operators are satisfied with its handling. 

Solution

This hydraulic tool for tramway wheels can be used in replacement of worn out wheels of Bombardier's Flexity tramways. 

Completion of instruction manual, work process update, validation and product data management closed this project.