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One of our European customers had enjoyed considerable success producing caravan manoeuvring systems in the growing leisure market, but they needed a new generation of ‘mover’ to maintain their position. It would not only have to look good and be lighter and easier to assemble – but it also had to be in production within six months.
Matt Garwood CEng. was appointed as project engineer:
“The project started with the customer approaching us to act as the technical lead for the motor and gearbox, which were to be core components of the new product. We drew up several concepts that met their requirements based on the preliminary brief. Happily, these were well received and so the preferred solution was progressed to prototype stage.
After testing however, we soon realised that the product would have to meet a number of new design criteria: a more restricted space envelope, higher loading and the addition of extra hardware which needed to be designed into the main housing.
These changes resulted in the need to abandon the first prototypes and investigate new methods of achieving the design goal. New ideas were put forward, investigated and some prototyped, but they were still not entirely successful.
It was at this stage that the customer revealed that they had been talking to another supplier who had a solution on the table, and this was considered to be ready for production. However, on validation of the competitor’s design we found that, although a very good concept, it was not a unit that could be made in considerable volume. Moreover, test data showed it was still not fully meeting the criteria and, since a prototype had broken under test a few days before, the strength of the design was questionable.
Commercially the clock was ticking and we knew we had to develop a workable solution. So, using the best features of all the concepts to date and through a detailed exchange of ideas with the customer’s R&D team we developed the makings of a robust design that would exceed all performance expectations.
We stress analysed several virtual 3D models and validated the design with detailed calculations and analysis. Every part of it was checked to ensure it was fit for purpose. Gear calculations were completed and all aluminium castings were studied using FEA for strength and resonance followed by practical testing. Component drawings were developed to ensure that suppliers would consistently supply parts that would make a consistent product. The design was analysed through FMEA, and so too was the process. All this helped to accelerate the development process and minimise costs.
Then finally, after the prototypes had successfully passed rigorous application testing on caravans, the customer gave the green light for volume production to start.
We created assembly instructions and then worked closely with our production team to construct a dedicated palletised-flow production line. The whole project was completed in logical sequence and at the passing of each project milestone we held a review meeting to ensure that the customer was fully aware of progress and to ensure that all actions were being followed up.
The result: production was launched on time and to cost, the new generation mover exceeded expectations, and the modern aesthetics, low weight and smooth operation were a huge hit with customers. But the icing on the cake has to be that the it won a European product design award, for which we were more than happy to take a great deal of credit.” |
