projects while working for bombardier transportation...
TRANSCRIPT
Projects while working for Bombardier Transportation, Canada
APTA Passenger seat – BART contract
Existing Vs New Passenger seat
BART contract, 775 trains for Bay Area Rapid Transit, US$1.5B. Responsible for mechanical integration of APTA
passenger seats:
• Challenged strategic passenger seat suppliers to provide technical recommendation before contract award
• Worked with seat supplier and industrial designer to develop existing seat to meet BART’s specification (APTA,
modularity, comfort, aesthetic) and integrated them within the train
• Liaised with seat supplier and prototype center to build soft and hard mock up, part of an extensive passenger
outreach
• Supplier management from engineering side during contract execution
• New seat advantages compared to existing seat: http://www.bart.gov/about/projects/cars/customer-feedback
Schedule of finishes – BART contract
Full scale mock up of two-thirds of a train
Responsible for Schedule of finishes:
• Managed industrial designer to define finishes of all visible surfaces inside, outside the train and cab area
• Worked with supply management to ensure sourcing of the finishes
• Supported prototype center to build a full scale mock up of two-thirds of a train for public outreach
• Unveiling of the mock up to the public:
http://www.youtube.com/watch?v=DrNyHvyb59A&list=PL5C1619308424340A
https://www.youtube.com/watch?v=n83PSQF1ycs
Schedule of finishes – R179 NYCT contract
R179 NYCT contract, 300 subway cars for Metropolitan Transportation Authority, US$ 599MM. Lead schedule of
finishes:
• Worked with suppliers to define finishes of all visible surfaces inside, outside the train and cab area (paint,
powder coat, anodizing, HPL, melaminium…) to meet MTA ‘s specification
• Worked with supply management to ensure sourcing of the finishes
• Got approval of every single finishes by liaising with customer
• Supported prototype center to build full scale mock up car with finishes as per production car
• Liaised with design center so finishes are properly defined on manufacturing drawings
• Defined the process to become a Bombardier’s standard
Full scale mock up of a cab car
Passenger seat – BiLevel contract
Make-Existing seats Vs Buy-New passenger seats
BiLevel train contract, 60 trains for GoTransit, CAD$ 200MM. Responsible for mechanical integration of:
• Passenger seats
- Seat supplier selection during bidding phase
- Supplier management from engineering side during contract execution
- Business case Make Vs Buy to convince internal customers (PM and Finance) and GoTransit
• Floor heaters from Notice To Proceed (NTP) to Preliminary Design Review (PDR)
• Stanchions, from NTP to PDR
• Plywood floor, from NTP to PDR
• Finished floor (carpet and Baultar embedded with High Performance Photoluminescent marking) from NTP to
PDR
Projects while working for LPA Niphan Systems, UK
Crocodile cable carrier for the Airbus A380
Triple Crocodile in use at London Heathrow airport
Quad Crocodile cable carrier
modeled with Catia V5R19
Responsible for the entire aircraft product range: business worth £1.3M/Year
• 3D Catia V5 assembly made of +1 200 parts
• Aluminium structure (H frame, trolley)
• Sheet metal folding (junction boxes, U channels, cover lids, connector holster)
• Water cutting (pivot arms, pivot plates)
• CNC machining (mounting blocks, packers)
• Welding (H frame, trolley, junction boxes, basket, stop post)
• Bonding (labels, door sealings)
• Anti corrosion painting
• Standard parts (thrust washers, bearings, castor wheels, fasteners, crimp tags, bump stops, terminal rails…)
• Packaging (transport frame, wiring diagram)
CROCODILE
Aircraft power supply connector
200V AC, 400Hz aircraft power supply connectors , equipped with PCB, pushbuttons, LED’s and insertion switch
Project ownership : from design through to product delivery
• 3D Catia V5 assembly made of 113 parts
• Plastic injection molding (main body, inner connection, switch plates)
• Rubber injection molding (front detachable, handle, cable bungs)
• Stamping (gasket)
• Sealing (filler, switch gasket ,“O” rings)
• CNC Machining (power and control tubes)
• Silver plating (power and control tubes)
• Standard parts (switches, LEDs and fasteners)
• Packaging (specially made box, assembly instruction sheet, health and safety data sheet)
Power supply connector designed
with Catia V5R17
Power supply connector used at airports in the UK
and overseas
Created winning conceptual design of
helicopter ground power supply connector
Confidential work not allowed to be shown to the public as the product is still under
development
Project for the National Defence and the Canadian Forces
Shore supply receptacle for Bombardier Transportation UK
Contract worth £1.4M
Project ownership : from design through to product delivery
• 3D Catia V5 assembly made of 162 parts
• Compression molding (mounting plate, cover lid, insulators)
• CNC Machining (back plate, contact pins, cover lid hinges, hinges,
switch shaft, switch shaft housing, handle)
• Sheet metal folding (switch bracket)
• Sand casting (handle)
• Sealing (“O” rings, foam gasket)
• Bonding (labels)
• Standard parts (3 positions switch, fasteners and crimp tags)
• Maintenance manual and technical manual
Shore Supply Receptacle designed
with Catia V5R19
Shore Supply Receptacle fitted on train
Victoria Line Upgrade and Sub Surface
lines Shore Supply Receptacle for
London Underground
Junction Box for Rhaetian Railway in Swizerland
UNESCO World Heritage Site
Contract worth £0.5M
Project ownership: from design brief through to product delivery
• 3D Catia V5 assembly made of 141 parts
• Sand casting (junction box, terminal block and cable gland)
• Sheet metal folding (lid cover)
• CNC Machining (junction box, terminal block, insulating plates,
cable gland)
• Stamping (gasket to achieve IP rating)
• Bonding and riveting (labels)
• Standard parts (crimp tags and fasteners)
• Anti corrosion painting painting
Junction box installed on train
Junction box designed with
Catia V5R17
Secondary locking mechanism for battery raft
Victoria Line Upgrade project, London underground
Bombardier Transportation UK
Battery raft with sliding tray modeled by the engineer in charge of the project
Project ownership : manufacturing and assembly drawings
• 3D Catia V5 assembly made of 18 parts
• CNC Machining (support plate, lead screw)
• Laser cutting (locking plate)
• Water jet cutting (locking arm)
• Welding (support sub assembly)
• Assembly (mechanism mounted to the frame with hugh bolts)
• Standard parts (torsion spring, fasteners, lead screw and trapezoidal
nut)
Secondary locking mechanism modeled with Catia V5R19
Projects while working for Compagnie Deutsch Orléans,
France
Jumper coil cable for trucks
Work accomplished:
• Carried out GD&T study
• Stack dimensioning study
• Created Assembly instruction
Automatic connection for Renault Laguna 3, FEA Compression test done with Cosmos Works
Connector fitted underneath rail of front seat:
• Plastic injection molding (connector molding,
upper and lower locking plate)
• Sheet metal folding (strengthening plate)
• Stamping and folding (hermaphrodite contacts)
Connector fitted on chassis, under front seat:
• Plastic injection molding (connector molding,
upper and lower locking plate, supporting plate)
• Flat spring
• Stamping and folding (hermaphrodite contacts)
Automatic connector installed Connector fitted underneath rail of front seat
Connector fitted on chassis, under front seat
Hermaphrodite contacts
F1 of Scuderia Ferrari used for the Canadian grand prix, June 2002
Modeling work done with Catia V5R15
Work done at university and during spare time
Modeling work achieved using the following modules:
•Generative Shape design
•Free style shape • Part design
• Assembly design
• Photo studio
Bachelor of Engineering Final year project : Tether car
• Defined and modeled the engine required (over square
engine, engine speed)
• Sized the front and rear axles (axles diameter,
bearings, tires and rims)
• Investigated the most suitable type of transmission
and calculated the bevel gear ratio
• Designed the fuel tank and sketched the chassis
• Modeled the bridle according to technical regulations
• DMU Kinematics (engine, universal joint, bevel gear)
Engine and universal joint transmission Bevel gear and rear axle
Tether car designed with Catia V5R13
Tether car
M.S in Automotive Engineering
Thesis: SAE Formula student car_path follower model
Characteristic of car
•Alloy steel pipes space frame chassis, TIG
welded, with engine mounted at the back
(increasing chassis’s rigidity)
•Front suspension: independent double wishbone
with push rod and bell crank mechanism and anti-
roll bar
• Rear suspension: independent double wishbone
with push rod and bell crank mechanism
•Rack and pinion steering system
•Fully locked differential
•Glass fiber bodywork (master model made of full
scale clay model, vacuum injection molded)
MSC.Adams/View model
• Car modeled as a linkage model
• Model equipped with a dummy engine and a locked limit
slip differential
• Fiala tire model
• PID controller
• The model is able to follow the racing line
3D Track under MSC.Adams/View
• Car driven around track to capture GPS data
• GPS data to create track on Microsoft Excel
• Excel-Adams software to generate road data file
SAE Formula student car 3D Track of Leeds, UK MSC.Adams model
Analysis of Aston Martin Vanquish’s double wishbone front suspension
Aston Martin
Vanquish’s double
wishbone front
suspension
MSC.Adams/View analysis
• 3G Bump load cases
• 1G braking load cases • 0,75G cornering load cases
ANSYS analysis
• 3G Bump load cases
• 1G braking load cases
• 0,75G cornering load cases
MBS: MSC.Adams/View analysis FEA: ANSYS analysis
Analysis on 2005 SAE Formula student car
2005 SAE Formula student car Bending stress of roll over bar
Frontal impact, at 30g, of
space frame chassis Torsional stiffness of space
frame chassis
