monthly logs sabre rail

Month: June 2014

Work-based supervisor: James Skitt Activities undertaken:

Introduction to Solidworks CAD software, briefly talked to about CAMWORKS, which is an addition to Solidworks and is used to generate CNC programs from models that are created in Solidworks. There is the drawing vault, which is also an addition to Solidworks and is used to store recently created drawings and there is the Q-Pulse document management system. This software allows for the creation of documents, whereby an Engineering Instruction or drawing can be attached, the author is specified and the approver is selected, whom of which will activate the document. This introduction gave an insight into how drawings should be created. The drawing techniques I learned was using centre lines all the time and making efficient use of the revolve and extrude features.

Assisting in the organising of warranties, which was a series of investigations on returned products. There was testing the diameters of actuator casings to ensure they do not exceed 206.9mm and assisting in the disassembly and reassembly of an interlock valve through starting with the sealing component and working down, removing each section and disassembling each section which would be to create overhaul engineering instructions. For a nitrile rubber O-ring, removing this component would normally have taken 20 minutes, but for me, it took less than 10 seconds! I also demonstrated how the nitrile ring could be removed through careful dismantling.

Introduction to tolerances. I started off with machined tolerances and gradually gained an understanding of the various different types of tolerances. For example, I learnt that for tolerances with fits, capital letters were used for holes and lower case letters were used for shafts.

Shown how to correctly arrange drawings, such that sectional views were to be produced from top or bottom views.

Stepped in for one of the technicians, in order to test the alignment of bore holes on brake cylinder casings. Prior to this, the pressure for each brake cylinder casing was tested to ensure they didn’t leak air. All parts passed the inspection. Each Brake cylinder casing was then inspected and a cover plate for this type of component was used to ensure that opposite holes lined up perfectly. Both sides were tested before the component was bubble wrapped and stockpiled in a cardboard box.

Shown how to implement the correct line types on engineering drawings, such as always putting green centre lines in for side and section views, red for dimensions, pink for text, yellow for hidden lines.

Shown about using the many features in Solidworks, but in much greater detail. For instance, greater use of hole wizard and cosmetic threads was used to implement screwthreads and holes at given specifications in Solidworks.

Shown a variety of techniques used to check documents into the vault, including the use of taking ownership and navigating existing models/drawings to modify them.

Shown how to create acme threads. The technique followed selecting a surface, creating a circle, creating a helix, creating a shape and extrude cutting the thread.

Shown how to create check sheets. This is a sheet listing all the dimensions that are required to be checked by the inspector or machine operator on which dimensions to check when creating components on a CNC machine. It also contains operations, the percentage to be checked, gauges to check dimensions and machines they are to be performed on.

Month: August 2014

Work-based supervisor: Rob Oxley Activities undertaken:

Continued work as per previous months, but was given a different set of EST distributor components.

Continued work on the Hydraulic Parking Brake Actuator.

I was required to redraw a shoebeam link as quickly as possible to meet the buyer’s expectations.

I was required to redraw some brake cylinder lever arms and bushes

Similar work activities as the previous months. On the next page are some images showing what has been taking place over the past 2 months. There was no work between 2nd and 17th August.

New knowledge acquired:

Continued work on drawings. See Below for examples.

New product introduction project- A variety of skills have been gained on practical work. Knowledge gained here includes removing the bolts from the hydraulic parking brake, such that a certain order was required. The order was such that the fluid screws on top needed to be removed first to allow the lubricant to be removed. After this, the appropriate wrenches needed to be selected, such that the bolts holding the two halves together needed to be loosened initially before being teased out with a smaller wrench. After this, the spindle and socket needed to be removed, which involved a pulling action. A cylinder then needed to be

removed using high pressure (3 bar). See Below for images of the work undertaken.

Inlet Valve Stem and Tripcock Shoe Beam holder.

Month: September 2014


Measuring a distributor diaphragm - I was required to use the shadowgraph to measure the dimensions of a diaphragm.

Comparing dimensions of existing CAD drawings with those shown on the test sheets. This involved checking that the dimensions shown on the sheet were not out of tolerance with the dimensions shown on the CAD drawing. See figure 6.

Developed a template for a cheese-head screw. This involved looking up the core diameter on the internet before using the maximum values from a BS standard template. The columns were very long and each spec had to be under the correct BA Thread Type.

Creating an excel document of a list of distributors from storage.

Produced a drawing for a damper removal tool.

Took the initiative to help out in a last minute effort to draw a Caliper Spacer Strut. This component had to be delivered to the customer as quickly as possible, so I stayed several minutes after finishing work to get the drawing completed. The Sales manager was relieved!

Measured the dimensions of 3 types of distributor components, including a restrictor valve, an in - shot valve and a quick service valve. This involved using the trimos. See Figures 4 & 5.

Worked with one of the compliance engineers to produce drawings for some Caliper Levers. Producing the drawings for this part was very challenging and great care needed to be taken to ensure that it was accurate. I had to quickly decide whether I would have the time to get the drawing completed in time for review by the sales/engineering manager and I decided that I did have time to complete the drawing, but had to work efficiently to complete them.

Measured the dimensions of a sandwich part for the Goods Passenger Brake Lever. Several techniques were shown throughout on the shadowgraph. See figure 7.

Produced models and drawings for a Goods Passenger Brake Lever. New knowledge acquired:

Figure 4 - The trimos is a tool used to measure the exact height.

New knowledge gained in this area includes greater knowledge of using the shadowgraph. This time though, I have learnt how to find the length of lines, such that 3 points are placed along the line and press FINISH to get the final value.

New knowledge of using the trimos measuring tool. The trimos is a tool used to measure height in mm. A probe was placed on an aluminium block, before pressing set and raising the probe before lowering the probe again gently onto the surface to be measured, with a value given.

Improved understanding of Solidworks. Learnt how to use the loft feature to extrude flexing profiles.

Improved understanding of tolerances, such that I can now distinguish between M2F and M2C rubber tolerances. (M2F is for tolerances without flash, M2C is for tolerances with flash.

For one of the projects I have been working on, I am now able to solve problems quicker. For example, I needed to mirror the profile of a calliper lever. However, I was having issues with trying to use the mirror feature. It would be a while before my supervisor could help me out, so I took the initiative to figure it out for myself. I realised this through selecting all the necessary extrusion features and the end result was that I managed to achieve the mirrored surface. See Caliper images below.

Right to left, shown is the Caliper Lever assembly as delivered, and the positioning of the bore holes. Finding the dimensions of the bore holes was particularly challenging and care needed to be taken

when drawing these components.

Figure 5 – P5 Valve Stems Figure 6 - Initial Sample Figure 7 – Goods Passenger Components

Month: October 2014


Measured and drew a Seal Support Ring. The shadowgraph needed to be used, although measuring this part wasn’t particularly easy.

Made changes to two breather moulding drawings. The radii needed to be changed on one of the drawings. My supervisor also wanted two radii to be changed on another drawing, which proved challenging.

Renumbered distributor drawings and reorganised them. All the parts were numbered as AB17- 00 but everything needed to be renumbered to 5028 – 000 - 900.

Continued producing caliper tools for one of the compliance engineers for the Brake Caliper project. For this month, I have been working on producing a chopsaw jig tool to allow the struts of the caliper lever assembly to be cut off with ease.

Produced drawings for the Delner Damper components. The piston model proved to be quite challenging because the holes needed to be positioned in a way that was quite complicated. The process I followed was to extrude the holes in before placing some hole wizard extrude cuts

Redrew components from 2D to Solidworks versions. This was done for the CAU2 parts. Similarly, the same process was done for the CAU2S parts. Approximately 20 DCRs were raised for the CAU2 parts. Cylinder Actuating Units (CAU)s, when air is applied to them, they move upwards, applying pressure to the brake pads on the train bogie, causing the vehicle to slow down.

Reviewed how the interlock valve works. From this, I have learnt that an interlock valve prevents coal wagon doors from over stroking when operated by the ram and requires air to one inlet to work in conjunction with the working port in an open condition, and with the third port in a closed condition.

Reviewed how the changeover valve works, such that the assembly works with the empty relay valve to ensure that the required brake cylinder pressure is achieved.

Reviewed how the emergency release valve works, such that pressure to the distributor needs to be completely drained of pressure to allow the vehicle to slow down rapidly.

Was asked to draw up some cylinder cover drawings. One drawing showing the machined version, the other a casting version. For the casting version, I needed to use dotted shapes to show where the machined sections would be performed.


Shown new techniques on the shadowgraph. This included being shown how to use the probe, whereby the points were obtained by moving the probe into the light. The probe works such that it obtains a point whenever light is detected.

Improved teamworking skills. Over the last few weeks, I have worked closely with the compliance engineer to determine the best methods of producing a tool to allow the struts to be cut off correctly. Below are several teamworking skills I have acquired:

i. Correcting the compliance engineer whenever he has made any mistakes, e.g dimensioning. For a clamp, when the compliance engineer explained that he wanted the 90 angle recess of a pin as a change to the design, I found that it would alter the circle in a way that would prevent it the two clamps from being fully clamped together.

Taking pictures for dismantling EI – Taking pictures for EIs has taught me how to document steps to undertake certain tasks. It has taught me how, by taking a clear picture of the process being undertaken.

Greater level of consideration as to how drawings should be organised. For this, I would ask for a priority lot from the Senior Compliance Engineer. I would update him on my progress at the end of each shift and ask him if the priorities had been changed.

ii. Suggesting improvements which could be made. For the chopsaw tool, there were some threads that I discovered we didn’t need, so I made some changes for the appropriate shape of the clamp.

iii. Made suggestions about the material properties and structure of the components. One example was the positioning of the threaded holes in relation to their location. They were too close to the edges when I needed to modify a block.

iv. Was asked to decide which type of pin would be better, a threaded pin or a dowel pin. I chose a dowel pin because it would provide a sturdier grip than the threaded pin.

v. To make it easier for both myself and the compliance engineer, older designs were archived off so they could be retrieved if necessary. In the case of the upper and lower clamps, these parts could easily be modified, so V shaped slots were used in place of the U shaped slots.

vi. Reviewed how the base plate of the Chopsaw jig assembly tool would fit into the Chopsaw. This involved looking at the Chopsaw dimensions and comparing with the tool.

vii. Looked at ways in which the Caliper Lever assembly could be tilted at an angle so both pins could be cut in one process. In order to communicate this to the compliance engineer, I needed to show this on the Solidworks drawing.

viii. For the parts to be fabricated, the tolerances were reviewed and changed to fall in line with the manufacturing process, e.g welding tolerances are bigger than manufacturing tolerances.. These dimensions were also whole numbers. Equal distances using ‘=’ were used instead of numbers with decimal numbers to avoid unnecessary complications with precision.

Always aim to keep tool designs as simple as possible, this makes them easier to manufacture, which saves time and cost.

Below are three different drawings of the chopsaw jig assembly. From left to right are the early versions to the latest version.

November 2014 Work-based supervisor: Rob Oxley Activities undertaken:

Continued tasks from last month.

Produced tools for one of the compliance engineers, including tools for BFC Reclamation and for the caliper tools. I also provided a Tool Maintenance Check Sheet to each of the drawings to enable the tools to be measured as part of a planned maintenance program.

Started producing drawings for CAU2S components. On one day, much of this included work on spring templates.

Compiled a list of all the part numbers which need freeing up. The purpose of this activity is to prevent too many part numbers accumulating, so narrowing the numbers down would make it easier to identify certain parts.

Was tasked with redrawing three CAU3 drawings for experimental purposes. These included the thrust start spindles and socket which would attach to the thrust start spindles.

A large number of drawings needed approval from the senior compliance engineer. I aimed to get all the drawings right first time and completed by the end of the day. I was fortunate to get them checked on the same day.

Was asked to help the technician with checking for faults on a set of 12’’ packing cups.

Was shown how to use an engraving tool to engrave the Caliper tools.

Assisted one of the compliance engineers in developing some standard parts.

Have drawn some VTA valve components. New knowledge acquired:

Producing Caliper Tool drawings and understanding the precision required for successful tools.

December 2014 Work-based supervisor: James Skitt Activities undertaken:

Examining the faults that have occurred on the counter spring packages.

Removed the spring package out of the CAU casing.

Removed bits of paint and dirt from the lubricated areas within the CAU casing. The bits were sampled for examination, mainly to see if they were what were causing the CAUs to work improperly.

The dents on the gable ring and the spring package tube needed to be line with the holes in the gable ring. A whole batch of these needed to be tested for alignment. Half of the batch was deemed incorrect.

The method of finding the dents on the gable ring involved pushes the gable ring down using a spring press tool. Eye protection was needed to be worn for this in case the spring popped out of the assembly. The spring back assembly is made up from the following components, the gable ring, the spring and the casing. A sample of each was removed from the stores except for the spring. I needed the old spring to see if it had been deformed in any way, causing the gable ring to fall out of line.

One of each component for the spring package was taken out of store, except the spring packages since a correct spring package and an incorrect spring package needed to be found.

Worked on producing the drawing for the counter spring package. Producing the spring was fairly complex and care had to be taken as to how it would look on the sectional view.

Developed a configuration drawing for the teethed hexagonal bolt.

Developing a configuration drawing for an imperial stud.

Converted drawings to dxf format-This involved selecting a flat face on a model, followed by right clicking and selecting ‘export to dxf’. The face was then saved in a folder and I then clicked save in the dxf converter box. This was required so subcontractors could produce components from the dxf file of the model.

Produced CAU test rig drawings for one of the senior compliance engineers.

Relabelled the part containers with new numbers to replace the old numbers. The simple procedure involved uploading an excel document to a printing software.

Examined the faults found in a solenoid valve. Was unable to show the solidworks drawing, so I had to open up the drawing as a DXF

file converted to a solidworks drawing and point out the dimensions to the sales/engineering manager.


Extra skills in part removal, such that the spring package needed to be removed

Fault finding skills. Examining the fault with the dents and the holes matching up was one example.

Using the spring press tool, the gable ring was pressed downwards.

Knowing how to produce configuration drawings. From this I have learnt that a design table needs to be created, and that each dimension needs to be renamed and then copied and pasted into each cell in the design table.

Improved knowledge on creating standard part tables from British and ISO standards. A good example of this is the metric stud table. To begin with, the studs had varying metal ends and nut ends, so a table needed to be created that reflected these variations.

Converted flat model faces to DXF files by selecting the face, right clicking and selecting ‘export to DXF file’, before clicking save to create the DXF file.

Understanding of electronics in machinery. In this case, I was told how the PLC for a CAU Test Rig requires inputs so that it can send signals to the machinery for testing. I also found that small amounts of grit can prevent the Test Rig from working properly. So it is important that the test rig is kept free of dirt.

Producing simple general tables for parts that do not require models. This simple technique involved placing a table on a blank sheet, filling in each of the spaces below and inserting a general table by copying in values and associated tolerances.

Improved knowledge on fault finding skills gained from working on the solenoid valve. From this, I learnt that the stem was out of line and thus causing pressure to be distorted.

Above is some of the work I have done on some studs and the configuration drawing to produce the appropriate studs. For a polymer lock nut, a simple table was used as the specification was already provided.

Images from left to right show the progress being made on fault examination.1.

January 2015 Work-based supervisor: Rob Oxley Activities undertaken:

Continued work on producing configurations for standard parts and creating new standard part drawings.

Made corrections to the tolerances on some flame cut plates by removing the tolerances from the thicknesses and labelling them ‘STOCK’ and replaced some machined tolerances with Flame cut tolerances. Prior to this, I needed to tell the supplier the correct tolerances on the drawing over the phone.

Began work on developing components for the Brake Cylinder Test Rig. Producing the drawing for the L plate was very complex and attention needed to be paid towards the positioning of the circles. This drawing was particularly difficult in that the dimensions needed to be arranged in a way that was symmetrically clear.

Taking observations of work on producing the new CAU test rig and gained an understanding of the pneumatic diagram for the old CAU test rig. See Figure 8.

Helped my supervisor with renumbering some P4 Distributor components.

Learned about the situation of reporting safety issues and quality issues with the team leaders. During a meeting prior to starting the day, it was brought to our attention that there was a slight breakdown in communication between team leaders and the engineering team. The compliance team was supposed to be showing the team leaders new techniques for engineering instructions, but ended up showing them to the operators. The result was that some operators didn’t quite understand what was expected and performed the tasks incorrectly.

Produced some representational drawings of the bearings and a load cell for the CAU Test Rig Assembly. The Test Rig Assembly I produced to show one of the senior compliance engineers how each of the components would sit in. See Figure 9.

Was shown how to produce a VTS by one of the compliance engineers. A VTS is a Verification to Specification process which is used to reverse engineer components that are no longer available.

Was asked to produce drawings for the PBAC Test Rig.

Negotiated with the purchasing manager and a client over some drawing dimensions, which involved pointing out the correct dimensions to the client.

Opening DXF files in a partial Solidworks drawing format.

Emailed one of the compliance engineers to delete certain drawings from the Solidworks vault.

Confirmed the correct part number for a spring to one of the technicians to avoid confusion over some drawings.


Figure 8 - This image shows the new CAU Test Rig. All the functions have been designed to be as user friendly as possible and there are easy access modules to perform any changes to the testing process.

February 2015 Work-based supervisor: Rob Oxley Activities undertaken:

Was told by my senior compliance engineer that any changes to revised drawings must be reported to the materials department to ensure that components are manufactured to the latest drawing issue.

Assisted one of the compliance engineers with the dismantling of a BFCB brake actuator. Images on the next page show this.

o Tasks for this activity were taking pictures of the team leader dismantling the actuator.

o Suggestions were made to the compliance engineer about removing the O-ring such that two picks should be used instead of one.

o Parts were then cleaned in the washer and the tools were returned to dedicated shadow boards.

o After the parts were cleaned, we had to find some containers. I asked one of the operators for a container. I did think about the effects on quality systems if I took one of the containers though. We used blue roll to clean the parts of muck and grime. I also made suggestions about the type of storage we should use. Also asked one of the operators on how to open the washer. On a skills level, I get greater sense of responsibility for my own actions for taking pictures of a rare and limited overhaul.

Produced drawings for BFC Components.

Produced drawings for the Brake Cylinder Cap Tool.

Produced drawings for SA66 Slack Adjusters.

Obtained information from the Technical Sales Manager for a Spring that needed a drawing producing very quickly. I processed the information that was made available, and was able to convert this into the information required to produce the drawing. I ensured that the drawing was forwarded to materials planning in a timely manner to ensure the springs could be ordered immediately.

Updated a VTS document to the latest format, which included extra dimensional checks and material research to be performed.

Agreed with the Operations manager that I would attend a presentation at ImechE. New knowledge acquired:

These images show the

dismantling of a BFC-B brake actuator. I took these photos when the most important stages of the dismantling process had been reached. So knowing what was most important was most important.

Greater understanding of how VTSs work. I learned that the manufacturing process for each part must be hypothesised to fit with the specification from the OEM.

Month: March 2015

Above is one of the VTSs I was examining to gain an understanding of how they work. This document is produced alongside the methodology for filling out and obtaining other VTS related documents outlined as follows:

Dimensions of 5 OEM samples

Material Analysis-Material Data Sheet

Drawing- 4-3-3 digit number Dimension of 5 samples from supplier/manufacturer, ISIR2

Certificate of conformity (COC)

Test Data Sheet (TDS)

QF-270


Began work on developing the drawing for a Circlip. A fair bit of negotiation with the compliance engineer was required including asking questions about which diagrams were most appropriate for the Circlip and asking if it was ok to undertake some measurements on dimensions that hadn’t been measured previously to prevent the initial sample inspection report from being invalidated.

Continued work on developing the drawings and subassemblies for the DRV Test Rig. The most challenging part of the assembly was producing the spring. Consideration needed to be taken towards the number of revolutions in the spring and how the ends of the spring could be extrude cut away. The cut extrusion was particularly important for determining the desired length.

Made suggestions to the machine shop teamleader about the best side to machine a part from. I was planning on showing the team leader directly, but I needed to check with my supervisor that it was ok.

Mentoring - Following a transfer from CAD operation to production engineering, I was required to get one of the assistant compliance engineers started on Solidworks. The whole process involved introducing the engineer to the whole Solidworks concept.

Production engineering - In the first two days, I have acquired a variety of knowledge relating to SA66s that has involved a number of different tasks:

o Reading through the SA66 component document. The purpose of this task was to familiarise myself with the dismantling, inspection, treatment and re-assembly steps. I focused primarily on the dismantling stages and referred to the component numbers.

o Reading through the OEM document for the SA66 treatment of the rear housing. This involved reading through the section, which I found to be vague and compared it with the attached BS ISO specifications to ensure most of the section was correct.

o Attaching letters from A to H inside one of the containers to each shelf. o Asked to conduct research into welding cast iron including how it was preheated and

welded.

Producing The EI document for cleaning the SA66 components. I made the document clearer with as many images as possible.

I needed to use Sage 200 to find existing part numbers for non – consumbales, such as hammers, screwdrivers etc.

How cast iron can be preheated and welded.

Diagram reading - To gain an understanding of how SA66s worked I needed to look at the diagrams to see which components were which.

Communicating with operators - Several instances this month involved me asking operators how the wash machines worked and how SA66 brakes were dismantled.

Was explained to about the format for filling out EIs. I discovered that the format of the EIs wasn’t good when shown in print preview and used the procedure to make them correct.

Updated Bill of Materials in Sage 200 for product being processed currently.


SA66 - Looked at the overhaul document for an SA66 brake. I read through the dismantling section and carefully observed how the brake was supposed to be dismantled. For example, the correct method holding the bellows of the brake while removing the hex bolts.

Welding- I have learnt how welding is grouped into production. This included welding operations for repair and production welds. I have learned about various types of welding, these have included manual (stick and MIG), plasma and friction welding. In particular, cast iron welding, which involves preheating iron to 450° and then maintaining a constant temperature of 300° afterwards. This was to keep the base temperature of the cast iron hot so that the weld would have a reduced risk of porosity. The cast iron was then allowed to cool naturally to reduce risks of cracks and distortion.

Dismantling - Using a video has helped me to gain a better understanding of the most important parts of the dismantling of the SA66 brakes and the knowledge I have gained from using tools such as the Allen keys, the ratchets and sockets, the mould grip, and using the impact gun. My methodology for dismantling has become more systematic and thoughtful as a result.

Learning how to correctly organise tools - The purpose of this quality control method is to keep all the tools organised and I looked at the tool shapes drawn on the blackboards to figure out which tools went where.

Producing documents to a standard format - Previously, I would set word documents out as I wished, but I now understand that they need to be of a higher standard in the workplace. For this reason, I format figures and tables using Insert Table of Figures and cross reference any steps taken.

Greater knowledge about providing instructions to operators - Producing EIs (Engineering Instructions) requires the engineer to pay close attention to each step produced and think very carefully about what they write, so not to cause any confusion.

Consumable Tools Parts List - Looking at this list has given me a greater insight into the tools numbered in such a way so they are incorporated into the EIs.

Sage - Was given an introduction to Sage including searching for a part number. I was then tasked with cross referencing assembly Bill of Materials (BOM) against a parts list. Where the BOM was incorrect, I had to amend it and update to the parts list.

Above is a screenshot of a Sage BOM, showing the list of necessary CAU components and the SA66 cleaning EI showing one of the operators degreasing the component prior to cleaning.

Month: April 2015


Raised two DCRs. One for a CAU flange Bush, which involved changing the material from BS 970 080M40 to BS 970 080M15. The second SA66 Flange Bush, this involved editing the note and the hardness values.

Continued updating Sage BOMs. Although no new knowledge has been acquired in this area, I find it easier to follow tasks involving the use of Sage.

Was required to undertake some research into carbonitriding and carburising. This research was fundamental in terms of finding an appropriate case depth so that it didn’t interfere with the +/-0.065mm diameter tolerance of the component. It was decided that carbonitriding was the preferred option.

Amended the cleaning document and ensured that the all the tool numbers were placed in the document.

Undertook hardness value measurements on the SA66 Flange Bush. This involved placing the component on a magnetic plate to prevent any movement. I used an electronic hardness tester.

Two SA66 Flange Bushes needed to be retained in a Rear Housing. I asked the treatment team leader to shot blast the two bushes to remove any paintwork so I had a base material to obtain accurate measurements. I also compared the hardness values of two CAU Flange Bushes and compared the results with their drawings.

Assisted one of the compliance engineers with measuring the diameter of a batch of cylinders. I had to take note of certain dimensions to keep record of the task at hand.

Measured covering seals. This involved using the shadowgraph to obtain the correct dimensions.

Looked up order code numbers in a Cromwell catalogue and made note of the name, quantity, tool number, order code, list price and offer price. I also needed to negotiate with the planner over which companies to purchase some Allen key sockets from.

Looked up suitable containers and foam for the flyrepair service for proposed tool storage methods. This was difficult because I needed to find a container that had square sides, a hinged lid and was above 73.5 litres. I found two types of Euro container, one was a 20C85 version at 74 litres, priced at £56, and another was made by Solent plastics and carried 88 litres, priced at £20. After a meeting with one of the compliance engineers, it was decided by the production manager that I should opt for a container with a hinged lid and could be locked to prevent anyone from looking inside and taking any tools. This then prompted me to look for padlocks, preferably coded and to look for a container with square sides, above 73.5 litres and a hinged lid. I managed to find a container that matched this description for just £20 (inc VAT).

Attended an ImechE meeting in York. I learnt from Grand Central Trains the importance of keeping up maintenance on the class 180 DMUs, which had been neglected. I also learnt about how the company is small and they rely heavily on passenger numbers.

Rang up Gallacher Seals to ask for the tolerances of the covering seals and ask them to supply a certificate of conformity. This was to complete an investigation for some covering seals for SA66.

I put enquiries out to various companies in the northeast of England for some grades of foam. I then forwarded the quotes to our materials department so they could purchase the foam.


Shown how to use the electronic hardness tester.

Research and development i) I have been tasked with conducting research into costs for various tools for a

cost cutting exercise. The most important aspects I have learnt from this is making note of the tool type product code, the RRP price and the offer price. I also made use of Sage 200 to find the names of the current tools and then match the name with that in the catalogue. I feel that making notes of offer prices is important in terms of helping the materials department to help keep the costs down.

ii) I have conducted research into contsiner sizes for tool storage for various production lines. I first calculated the volume of space required to store the tools and researched alternative methods of storing them. The important aspects were the size and weight of the storage methods. During the research, the criteria was altered to ensure that the storage containers could be locked.

iii) I Developed the idea of using the storage containers by finding an 88 litre container with a hinged lid and a hold could be drilled through the lid and the container to allow a coded lock to be fitted.

An understanding of how carbonitriding and carburising work. I have learnt that carbonitriding is applied to produce a hard and wear resistant surface and is a mixture of carbon and nitrogen. Case depths of 0.025mm and up to 0.75mm can be achieved. It is also particularly suited towards mass production. Distortion is also reduced due to the lower temperature required for carbonitriding.

Carburizing, however requires that it be deposited as fairly thick layers. But is much less likely to fail from impact loading due to having a softer core. The hardening process tends to involve dipping the metal in oil, polymer/water solution or salt. The quenching that follows reduces peak stress and crack initiation.

Learned about negotiating between departments on what product best suits the need of the business when taking into consideration of cost and purpose for the task.

One of the projects I have been working on is the Flying Fitter Tool Kit. This is a system whereby an urgent brake, damper or valve can be repaired either in-house or off-site at the customer’s location.

From left to right, the electronic hardness tester, set to Rockwell, slide down the tube quickly, position on material firmly and release, value is given.

From left to right, the prototype for one of the tool trays for the flying fitter tool kit. I had to think carefully about how the tools should be positioned as I wanted to get a whole set for a certain type of operation. This material was also quite difficult to cut, so with some advice from tripak

and the production engineer I should be able to better cut the material in the future.

From left to right: 1. SA66 unit. 2. A spanner was used to remove the screws to take the plate off. 3. The bellows is raised to allow the other screws to be removed. 4. An air gun is used to remove any difficult screws. 5 Removing the Spindle reveals the amount of dirt and grime in the unit. 6. An Allen key is used to remove the cover.

Month: May 2015


Warranties & Customer Returns - For the past few days I have been introduced and shown how to conduct a warranty investigation on return assemblies with report failure modes. These were for CAU2 Brake Actuators and Koni Dampers.

Producing a warranty investigation report. Testing the adjusting nuts for CAU actuators to replicate failure modes.

Testing the distances between the centre of a trunnion block hold and a flat face of the trunnion block on SA66 Brake Actuators to check if the distance was outside specification.

Went on an ImechE visit to London and learn about the projects that the participants had undertaken. Many of them were based upon the current activities of the rail industry

Went on an ImechE visit to Newcastle to learn about how Nexus undertakes measurements and testing on its networks. Most specifically, I was shown to the Plasser & Theurer Tamper and how it worked in conjunction with the worker’s needs. The machine itself was highly advanced and featured user friendly driver’s controls in addition to a braking room.

Assisted the compliance engineer with testing some 77v WSPs. This involved testing the values on the production test rig to ensure they all met the performance criteria.

Used the Faro Arm to measure the distance between two holes. The steps are outlined below.

Dismantled a CAU2S for warranties. To help investigate the failure mode identified during it’s performance examination. Particular care needed to be taken due to a spring being loaded inside.


1. Faro Arm. 2. The plane option is selected. 3. The points are placed for the plane. 4. The

points are recorder. 5. The circle option is then selected and points are placed on the inside of the circle. 6. The circle is recorded. 7. The same procedure is done for the other circle and the result is obtained by selecting the two circles and dragging away. 8. The component needs to be glued in place to prevent any movement.

Clockwise from top left, The wording format for tagging units, a typical CR/WAR document layout, Sabre tag, paperwork, differences between a warranty (left) and Customer Return (right).

Warranties & Customer Returns:

Working on warranties and customer returns was very demanding and the customer always wanted the unit completed in a timely manner.

Process: i. Searching for warranties – check if they are outstanding or closed by searching

in Q – Pulse. ii. Used the blank warranty form to plan out the investigation process. iii. For new warranties, this starts with filling in a goods inward sheet, including the

overhaul date, the warranty date, warranty period, serial number, colour, concern, Original SOR and original WO.

iv. Created new warranty claim numbers in Q – Pulse. Then filled in the investigation, which included finding the root cause of the failure. Then identify and implementing relating corrective actions.

Knowing how to accurately measure a distance using analogue equipment.

Knowing how to assemble a product before testing it.

From left to right, the measuring procedure for trunnion blocks. The measurement tool took an initial measurement, e.g 42, then the closest matching lines determined the next decimal place.

Various controls needed to be operated in accordance with the provided testing instruction.

Figure 10 – the WSP test rig with 77v WSP undergoing testing.

Testing 77v WSPs:

Involved using a pre-test for enhanced units, performance tests, low pressure tests, drop out test, sealing test and an after test. The connectors also needed to be attached to the correct leads and the air tubes firmly secured to the portholes. See Figure 11.

Figure 11 – Close up of tubes and positioning of WSP.