Belfast Product Design: CAD, Prototyping and Engineering
Generating new product design concepts, developing prototypes and delivering production designs
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Industrial

This case study is an example of how complex mechanisms can be prototyped and refined to ensure cost effective manufacture and 100% reliability. Detailed part engineering and materials processing were required to achieve the final result

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Industrial Product Development

CASE STUDY :

HIGH VOLTAGE SWITCHGEAR

Completed while Project Manager / Design Engineer at IDC. (images creds)

This project involved the development of two novel mechanisms. Designed to deliver 80 kJ of energy and quickly switch the position of high-voltage switchgear in order to prevent arcing and mitigate the risk of explosion. Both mechanisms can be operated manually, meaning that testing, safety and risk management were important aspects of the development process.

 
“Final production costs were always important in Ryan’s mind, he would show the prototype method of manufacture but would always back it up with the production vision having deep consideration for Design for Manufacture and Assembly techniques to achieve the final target costs.

In summary Ryan is an excellent professional engineer with an eagerness and capability to learn at a rapid rate with an infectious enthusiasm for all engineering. ”
— John Casey, Director and Engineer
 
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EARLY PROTOTYPES

The fundamentals of the new design concept were explored using a reduced scale wooden prototype. It also provided a useful tool for communicating the concept design to other project stakeholders and achieve buy in.

 
 
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3D CAD MODEL

The circuit breaker assembly contains many moving parts, springs and inter-locks. Three cams rotate around a central axis and the output rotation was used to switch the contactors of a 12,500 V supply. The 3D model illustrated how component assemblies interact with one another through their full range of movement.

 
 
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EXPERIMENTAL TESTING

The equipment was designed to withstand long periods without any servicing or actuation, therefore rigorous verification testing was an important element of this project. High speed video was used to evaluate the dynamic performance of the product and a combination of endurance testing (destructive) and non-destructive operational testing (NDT) was performed.

 
 
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DETAILED ENGINEERING

A design file was produced including a 2D drawing pack of all components, detailed with tolerances to ensure reliable manufacture and assembly. The high-impact loads and rigorous industry test specification meant that a variety of coating processes and lubricants were used to attain the strength, friction and wear properties required.

 
 
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PRODUCTION PROTOTYPES

A batch of production prototypes were made to experimentally verify the required performance and demonstrate operation of the mechanism to external project stakeholders. The final product was a safe, easy-to-use and compact solution which provided low-cost in combination with high reliability.