portfolio
DESCRIPTION
Design PortfolioTRANSCRIPT
2010
David Coombes
Design Portfolio
BEng (Hons) - Manufacturing Engineering and Management
Diploma in Industrial Studies (DIS)
MSc - Advanced Manufacturing Engineering and Management
I believe a top engineer should not only
possess great theoretical and analytical skills
gained through training and experience but
also the ability to inspire innovation, drive
improvement and sustain success.
With the use of a combination of skills sets
(such as: Creativity, Analytical and
Constructive) the individual, and team, can
be propelled to a greater level of
achievement.
My diverse background and skills make me a
valuable member of any team. I bring fresh
ideas grounded in solid engineering
fundamentals, making me an asset in all
problem solving situations.
Take a look…
Feeder-pan Motor Housing Jig
Summary; problems arose in the field with
inaccurate mounting of the motor housing to
the feeder-pan. The housing was mounted
incorrectly and not concentric to the hole.
This lack of concentricity caused the seals to
be misaligned and oil leakages occurred.
Project Description; the need for a jig to aid
the mounting of the housing was essential.
Initial step was to view the parts in question.
A plug was needed which sat in each end of
the housing, and a mock shaft through the
middle. With correct tolerances, this should
ensure concentricity. By using nominal
dimensions for the model, tolerances could
be added to the drawing later.
Treadmill Design
Summary; the task was to design a treadmill
interface, as part of a final year module. The
task included; design and analysis,
manufacture analysis, ergonomic analysis
and structural analysis.
Project Description; during a series of
lectures, and in any spare time, a design was
formulated and analysed from numerous
different perspectives. The images show the
analysis from these viewpoints. These
perspectives were: aesthetics, manufacturing,
ergonomics, stress and strain and marketing.
Phone
Summary; as a purely design focused project; the task was
to design a mobile phone to be used by the less able and
elderly.
Project Description; the initial stage of this project was
information gathering. This came in the form a
questionnaire, answered by the target market. From this
feedback, it was found that; a flip phone, with larger
buttons, simple menu, large display, tactile buttons and
sounds accessibility. With this project solely a design
related one; most of the considerations went into the
design rather than production. Functionality was
considered more than form, due to the nature of the user.
Steel Hydraulic Pipes
Summary; new hydraulic system, lead to the need for new
hydraulic pipes. These pipes connected the manifold to
certain pumps, valves and back to the reservoir.
Project Description; by using the information from
within the office, and from information from the line. It
was relatively simple to understand the ports in which the
pipes should connect. The distance between the two
locations was found, in all three dimensions. This was
double checked using the CAD model, and all avoidances
were found using the model. This distance and the areas to
avoid, dictated the profile of the pipes.
Problems; a major problem occurred due to not being
able to test the pipes until the machine was built. By
organising a one-off batch from the supplier, when the
first machine was ready, all design changes could be
captured. This saved a significant amount of money, due
to not having stock which was not useable, and also
ensured quality was maintained.
Wiring Diagrams
Summary; keeping all diagrams up to date is essential
within any manufacturing organisation. The project
consisted of ensuring all wiring diagrams were up to date
and correct any changes.
Project Description; by contacting the suppliers of the
electric equipment, it was possible to get all drawings for
the systems that they provided. These were then put onto
the system using a 2D CAD system.
Problems; a major hindrance within this project came
with the revision of drawings received from the suppliers.
The suppliers did not want to supply current revisions,
due to the possibility of losing a customer. With this in
mind, all drawings supplied were checked against a
current machine, to ensure they were up-to-date and all
changes were completed if necessary.
Power-Pack Trolley
Summary; there was a need for moving a complete power-
pack (engine) from the bay in which it is built to the bay in
which it is fitted to the machine.
Project Description; the request was made by
production. The first step was to understand the needs of
production; once this was completed a rough drawing was
agreed with them regarding the overall design of the
trolley. Research regarding details was needed after the
general design was finalised. The maximum and minimum
size of the power-packs indicated the degree of
adjustability needed. The maximum weight would dictate
the strength of the wheels needed. A safety factor of 3 was
considered. The maximum weight of any individual
power-pack was 2,500kg. Each caster would be loaded with
a maximum of 625kg. The safety factor of 3 ensured that
all casters could hold weights up to 1,875kg (2,000kg).
Reinforcing Plates
Summary; an extremely old machine had been returned
for service, due to the excessive forces on the chassis from
where the jaw crusher sat, the chassis had cracked.
Reinforcing plates were needed to be welding on to
prevent the crack from spreading.
Project Description; initially, photographs of the cracked
chassis were taken to determine the extent of the damage
and to indicate the areas the plates need to cover. Once
completed, the drawings were drawn up; one-off set was
made in fabrication and fitted to the machine. Within this
project, form was not considered. It was purely a
functional item and was designed to complete the job.
Problems; there was one severe problem encountered.
The plates welded to the chassis would cause the jaw box
to sit a higher height than before. This could potentially
result in a clash with the feeder, which sat only a few
millimetres above the jaw box. After investigating the
clearance, it was found that the jaw box would be too
high. Smaller plates were made for the feeder to sit on, to
maintain the clearance. This new height was checked to
ensure it was still inside transport regulations.
New Main Conveyor
Summary; an alteration in cones used on the cone
crushers required the development of a complete new
machine. The re-design of the main conveyor was my role.
Project Description; to save a significant amount of time,
the design was completed by altering an existing conveyor.
Where possible, to reduce waste and as part as an
initiative to implement lean manufacturing, current parts
were used. This could not be achieved in numerous
situations, in these situations entirely new parts were
created. Alongside the generation of the 3D model,
engineering drawings for all components were also
needed. Problems; one problem encountered, was during the
design of the “nip guard”. This guard is used to ensure no
debris attaches to the head drum and damages the belt.
The new conveyor was wider than previous conveyors, so
previous nip guards could be altered, and the change
accounted for, resulting in less time re-designing. It was
found that due to the bigger new head drum, to power the
wider belt, the old nip guard design would collide. A
prototype was created, incorporating a new length which
should clear the new head drum. This then could be
tested on an existing conveyor, using the new guard and
bigger drum. The prototype work perfectly, and the new
guard was sent to production.
CV
