We were asked to create an electric points actuator using a brushless motor to prolong the life of a crucial piece of equipment. Our solution delivered capability beyond the requirement, offering further future efficiency, safety and process improvements.

PROCESS

UNSOLVED IDEA / PROBLEM

Initial meeting was held with the client to discuss their need for a brushless servo motor for a rail points actuator to improve its longevity. Together we considered existing material and systems and EMP Designs saw the opportunity to improve maintenance intervals, thereby reducing risks significantly.

INVENTION

Considering new technologies, EMP Designs invented a completely new actuator that met the brief, offered a soft closure solution further improving efficiency, and opened scope for feedback data & systems. We delivered 3D space models, renderings, and 3D printed media to the client.

DESIGN DETAIL

Once the concept was approved, EMP Designs designed all the detailed mechanical and electronic requirements.

REVIEW

3D data and concepts were reviewed with the client.

PROTOTYPE

EMP Designs built a high-quality prototype in-house and then tested this with the client in a full operating environment.

DEVELOP

Testing resulted in the client correcting the original specification details. The product functioned well in its live environment. Further developments for improving capability were identified for the future.

BUILD

We built a small batch of further prototypes in-house, which are currently undergoing prolonged testing with the client. The product capability is beyond the brief, with potential for far-reaching safety, efficiency, and maintenance improvements.