Power Distribution Box

A Tier 1 Aerospace supplier sought to design primary power distribution boxes for an executive jet. Engaged as Contract Design Engineer to design removable main and backup boxes and fixed trays. Re-engineered existing concept design; incorporated new location/locking mechanism; redesigned box/fixed tray enclosures; liaised with supplier to ensure manufacture within cost budget/timescales; performed stress calculations for normal use/shock conditions; routed cables within boxes. Part of team that delivered ‘world’s most technologically advanced power distribution system’ for demanding client within challenging deadline.

Handling System

A Major Defence Contractor supplies Weapons Handling Systems for submarines. Engaged as contract Design Engineer to provide sub-system designs. Developed design solutions against stringent customer requirements; checked designs for team of 9 Engineers prior to review by Chief Engineers; optimised setting positions for torpedo stowage to launch tubes; created weld strength design assessment; and overcame supply/quality issues with critical component design. Played key role in design of WHS for first-of-class submarines currently undergoing sea trials for Spanish and South Korean navies.

Robotic Butchery

AMARC (an automation research centre at University of Bristol) led a 3 year EU-funded project to investigate automation of labour-intensive meat processing tasks. As Research Associate, led AMARC contribution to identify viable butchery tasks for automation. Supervised research team; co-invented carcass vertebrae measuring method; wrote overall system/partner sub-system specifications; coordinated trials at end-user site; demonstrated system at international trade exhibition and wrote article showcasing system for major industry publication. Succeeded in developing world’s first robotic butchery system offering improved accuracy, increasing yield and profitability over manual method.

Design Projects

Edwards Vacuum Ltd. sought to develop a head assembly to improve the efficiency of their abatement systems for toxic and global warming gases used in the semiconductor industry. Engaged as Design Consultant to provide design solution. Agreed specification with development laboratory; liaised with customer-based teams to ensure compatibility with existing production machines; created concept designs for senior management review; completed detailed design; created and checked manufacturing drawings; purchased parts; and oversaw production of installation drawings for field trials. Succeeded in providing robust design, and variants, with significant performance and efficiency benefits for customer trials, with 5 patents granted or pending.

Head Assy for Exhaust Gas Abatement

British Nuclear Group (BNG) sought to bid for the design contract for a £100m nuclear waste processing/storage facility (ICEDA) in collaboration with Freyssinet and Vinci (France). Engaged as Lead Engineer to develop a competitive bid. Reviewed ITT; coordinated inputs from multi-disciplinary team; contributed to creation of comprehensive design; developed waste streams workflow; provided responses to ITT requirements; and liaised with Freyssinet and Vinci Engineers. Succeeded in delivering competitive bid that received Government backing in the form of sign-off by UK Business Minister. This was a selected bid by EDF for the project.

Nuclear Waste Reprocessing Facility

Imperial Process Ltd had developed process equipment to provide tobacco expansion using an alternative to CFCs. Engaged as Design Consultant to improve equipment design by Aeroform Ltd. Developed design; provided formal HAZOP assessment response; specified key parts; optimised onsite process parameters; redesigned pressure vessel seal; re-engineered cooling system; wrote operational manuals; supervised subcontract suppliers; wrote control specification; and provided post-handover support. Succeeded in delivering process equipment design to support novel process to meet Montreal Protocol for replacing CFC’s.

Tobacco Expansion Process

Metrology

As a design engineer at Renishaw I had design responsibility for the MP7/8/9 probe assemblies and styli range signing permits and concessions necessary to maintain production; probe sales were 300 per month when I left in 1988. Additionally I had new design projects such as the copy milling (scanning) probe shown. I designed and issued to production a number of products including MP8 probe with Shank Switch-On, a contact probe, the original machine checking gauge and styli with diameter 0.5 and 1 mm balls.

A selection of projects on which I have had significant design input.