Fire service innovation Case study – Pailton Engineering
FOCUS
FOR ONE Pailton Engineering customer, the design and development engineers were challenged with producing a next generation bevel box that could endure high levels of operation in high moisture conditions. Also known as a mitre box, the integral part transmits torque in the steering system across two steering shafts at a 90 degree angle. For their customer, the engineers aimed to
redesign the bevel box ultimately to keep water out and lubrication in, even in extremely cold and wet environments. The team made strategic design upgrades of this steering component – including a unique lubrication that would enable operation in temperatures as low as -40 degrees Celsius. Additionally, they added new housings to the design in a bid to improve sealing capabilities. With new design additions in place, they
validated their design options with a bespoke 56 week long testing programme. During the time, the test bevel boxes endured a sustained period of submersion, salt and grit exposure and extremely low temperatures, all while the bevel boxes were in continuous operation. Emma Cygan, design and development engineer at Pailton Engineering, explained: ‘We set up a bespoke, brand new test station at Pailton Engineering, to make sure that our latest bevel box design was fit for purpose.
This involved submerging the generation three bevel box in saltwater for extensive periods of dynamic testing and evaluation. The bevel boxes were subjected to dynamic submersion and low temperatures. ‘Quite frankly, we have abused these bevel
boxes. We wanted to see if the sealing design features, such as the serration cover and outer full cover, could endure this continual operation, salt and grit exposure and incredibly low temperatures, all while keeping water out of the component. We knew if the bevel box could handle this, then enduring real world extremes would be easy.’
Moment of truth
The 56 week testing programme was a long time to wait to see if the part had lived up to claims. When the nailbiting day finally arrived, the engineers were thrilled to find that even after the intense moisture and grit exposure, no trace of water had entered the vital component. While the bevel boxes externally showed evidence of the conditions they had faced, the internal characteristics of the bevel box were pristine – no sign of corrosion, moisture or contamination. To complement this, Pailton Engineering also sent the bevel box to external testing facilities. Here, the bevel box was found to meet ASTM
Case study continues overleaf
www.frmjournal.com APRIL 2020 37
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