Case Studies
Please find below a selection of Osborn Design mechanical engineering case studies using 2D and 3D CAD software to produce mechanical engineering design solutions covering various sectors.
If you would like to discuss your own project with us please do not hesitate to contact us.
Case study 1 – Lidl, Luton UK – RDC Warehouse Racking & Conveyor System.
Summary – Production of 3D CAD BIM models of a new design warehouse racking and conveyor system for one of Lidl’s largest regional distribution centres in the UK, located near Houghton Regis.
Scope of design – We were asked to produce 3D CAD BIM models of a new design warehouse racking and conveyor system from 2D AutoCAD design drawings, elevations and sections for Jungheinrich UK Ltd, the main contractor. The models were to be imported into a federated Revit BIM CAD model of the distribution centre for clash detection, along with subsequent building services models to be added later. Any clashes would lead to remedial design work. This would ensure the actual building project progressed with as little disruption as possible.
Outcome – The CAD models were successfully imported into the federated Revit BIM CAD model and remedial design changes made to clashes and design errors found. This updated federated model was then later used to show up and resolve building services clashes from models supplied by contractors.
Case study 2 – THOR Photomedicine Ltd – Mechanical Support System Investigation and Re-design
Summary – An intermittent fault within the mechanical support system was resolved, and remedial design improvements implemented and rolled out on in-service units.
Scope of design – We were consulted to investigate an intermittent fault within the mechanical support system of Light Pod machines out in the field, and to come up with solutions within current production design limits.
Outcome – After statistical data analysis, laboratory tests, metallurgy investigation using electron microscopes, engineering calculations and design analysis, we were able to resolve the problem. Remedial design improvements have been implemented and rolled out on in-service units as a retrofit solution.
Case study 3 – Class 800 (IEP) Hitachi Train – Door Maintenance Training Rig.
Summary – A Door Maintenance Training Rig was designed, manufactured and commissioned for Hitachi Rail Europe Ltd for the North Pole TMC, London.
Scope of design – The design remit was for the production of a Door Rig from 3D CAD files and 2D drawings based on a legacy Rig in Japan, that would accommodate the new 800 Class train door leaf, panels, mechanisms and ancillary equipment.
Using our 3D CAD software we were able to convert the legacy ‘step’ and ‘iges’ 3D files into editable 3D CAD models. We also produced 3D CAD models and 2D .dwg drawings from 2D .pdf drawings from suppliers such as TDS. Once we had assembled the full door rig as a CAD model we then proceeded to modify the frame and panels to accommodate the new equipment. We then issued a 3D CAD file of the rig assembly with associated 2D production drawings.
Outcome – The project was successfully delivered on time and on budget, and commissioned at the London depot. A second door rig was later produced for another depot based on this new design.
Case study 4 – Overhead High Pressure Water Spray Equipment for removing sludge from articulated & tipper lorry trailers for Anglian Water.
Summary – In collaboration with Archway TCS Ltd high pressure water spray equipment and supporting steel work was designed, manufactured and commissioned for Anglian Water.
Scope of design – Using 3D CAD modelling software and 2D AutoCAD architectural drawings, combined with engineering calcs and design data from articulated and tipper lorry trailer manufacturers, we arrived at a suitable design. 2D detail drawings of parts were exported from the 3D model for manufacture, and ‘snapshot views’ of 3D warehouse building to aid steel work to building assembly.
External ‘drive through’ spray wash and kiosk of ancillary equipment were also designed and installed.
Outcome – All equipment was successfully installed and commissioned at the Great Billing site.
Case study 5 – Servo Assisted Towing Post for hydraulic model testing at Cranfield University.
Summary – In collaboration with Those Engineers Ltd a towing post for testing models in a wave testing tank was designed, manufactured and commissioned for Cranfield University. We worked on the mechanical design using 2D & 3D CAD.
Scope of design – The Tow Post consisted of a servo assisted carriage responding to changes in vertical force. Inertia was reduced by a counter balance to the sliding carriage, although a small but negligible moment was incurred. A sensor served to achieve sensitive control to produce ‘zero mass’ of the carriage relative to the model. Electronic gyros fastened to the model measured angular motion of the model, namely Pitch (nodding), Yaw (turning) Roll (side to side) and linear motion Sway (x), Surge (y) and Heave (z). The drag force was also measured using a strain gauge mounted on the top of the carriage which is pivoted in the middle.
Outcome – The project was successfully delivered and commissioned.
