Our Projects

Mega Projects

AutoHaul Project

Rio Tinto Railway Expansion Projects

AutoHaul (2013-2016) is a project implementing driverless train capability on the Rio Tinto heavy-haul rail network. AutoHaul, currently in the installation/commissioning phase, is a significant, high profile project; World-first on a heavy haul railway. ReconEng was the project tier-one contractor for complex mechanical sub-systems design and components supply, as well as the lead Engineering consultant for the project. The project design phase lasted two years and during the installation phase ReconEng supplied more than 6000 parts, approximately 3 tonnes of material per week for six months.

Client:
Ansaldo-STS

Location:
Pilbara, WA

Services:
Engineering Design and Manufacturing

Sector:
Iron Ore



Mega Projects

ECP / DA Project

Rio Tinto Railway Expansion Projects

ECP / DA (2011-2013) was the project implementing electronic braking control on the Rio Tinto heavy-haul trains. ReconEng was the tier-one contractor for complex mechanical sub-systems design and components supply, as well as the lead Engineering consultant for the project. During the design phase ReconEng was tasked with systems installation design and components supply, including fiberglass OEM consoles re-design and supply, as well as the mechanical components for control systems installation. At the installation phase of the project, doubling of the contract supply rate was required and successfully achieved.

Client:
Ansaldo-STS

Location:
Pilbara, WA

Services:
Engineering Design and Manufacturing

Sector:
Iron Ore



Mega Projects

ECP Driver’s Consoles

Complex, High-Value Systems Design

As part of the ECP project ReconEng was tasked with design and supply of new OEM fiberglass dashboards for GE locomotives. The design required adding a new ECP screen to the OEM console layout (which includes two existing screens), as well as several new instruments. The design allowed no increase in the existing footprint of the console. The prototype design, manufacture, onsite delivery and testing was successfully completed in only seven weeks. On successful testing of the prototype, ReconEng supplied 74 dashboards for the project.

Client:
Ansaldo-STS

Location:
Pilbara, WA

Services:
Engineering Design and Manufacturing

Sector:
Iron Ore



Mega Projects

AutoHaul BTM Antenna System

Automating Toxic, Unsafe Processes

As part of the AutoHaul project, ReconEng completed design, testing and supply of the Balise Transmission Module (BTM) frames for mounting the main system transceivers on the locomotive undersides. The design required for two BTM antennas per locomotive, alignment and interference specifications, as well as finite element analysis validation. The designs also overcame space and clash restrictions on the locomotive underside, as well as achieve ease of maintenance and installation. On successful completion of design and prototype testing, ReconEng supplied all BTM antenna frames for the project installation phase.

Client:
Ansaldo-STS

Location:
Pilbara, WA

Services:
Engineering Design and Manufacturing

Sector:
Iron Ore



Mega Projects

SD 100L Samples Generator

Automating Toxic, Unsafe Processes

Automatic system development designed for continuous production of Nickel samples for product content analysis. The system was required to produce fine, crushed and screened samples of the plant Nickel product for chromatography.

Labour-free, high safety, high productivity operation and qualified samples collection for analysis. Full project design, plant process integration, implementation and onsite commissioning at Murrin Murrin, WA. System achieved more than eight times productivity improvement with improved safety and 24/7 operation.

Client:
Glencore-Xstrata

Location:
Murrin Murrin, WA

Services:
Turnkey Engineering Systems Design

Sector:
Nickel



Mega Projects

Deer Park Bypass Project

Solutions for Applications with No Standard Solutions

Special application development designed for high capacity, high angle cutting of large roll-formed steel sheets for the construction phase of Melbourne’s Western Freeway. At a late stage of the project it was identified that no solution existed for manufacturing large design sound wall sections. ReconEng was tasked with designing a large capacity steel-cutting solution with ±70° mitre angle. The design successfully achieved all requirements and ReconEng performance on the project was one of the key factors which contributed to the Deer Park Bypass opening eight months ahead of schedule.

Client:
ARM Rollforming

Location:
Melbourne, VIC

Services:
Turnkey Engineering Systems Design

Sector:
Construction



Special Application Projects

NGS 150 Nano-Glass Saw

High-Precision Applications

Development of a cutting solution for small diameter glass tubing requiring high-precision, fine-tolerance operation to achieve a quality pass cut. High-precision diamond-disc saw for semi-automatic cutting of nano-glass tubing with the outside diameter down to 360 micron. High-precision rotational assembly with micron concentricity, as well as high-stability cutting stroke control. The implemented solution reduced the cut reject rate by more than 90 per cent. Full project design, implementation, and on-site commissioning in Melbourne, VIC.

Client:
Trajan Medical

Location:
Melbourne, VIC

Services:
Turnkey Engineering Systems Design

Sector:
Medical Manufacturing



Special Application Projects

FSBR Robotic Riveting System

Never Before Tried Systems and Concepts Development

FSBR (2012-2015) was a development of a joining system which employs a never-before implemented concept for making riveted Aluminium joints. The concept was researched by GM and CSIRO and ReconEng was selected as the contractor for machine-tool development and robotic integration suitable for wide-scale implementation. Development involved integrating multiple mechanical and electrical sub-systems, while achieving high-speed and high-reliability demands of auto manufacturing. Prototype final integration and commissioning were completed in 2015 and the process is to undergo trials in the US to assess suitability for GM plant implementation.

Client:
GM LLC

Location:
Detroit, MI

Services:
Turnkey Engineering Systems Design

Sector:
Auto Manufacturing



Special Application Projects

ATM-20 Mortice Lock Test Machine

High-Speed Precision Functionality Testing

ATM-20 is an automatic test machine designed for high-speed functionality testing of mortice locks. ATM- 20 performs 13 tests with a total 54 actions and checks on each lock in 17 seconds. Typical testing throughput is 1400 locks tested per day over two shifts. Project included on-site commissioning as part of Assa Abloy mortice lock production line development.

Client:
Assa Abloy

Location:
Melbourne, VIC

Services:
Turnkey Engineering Systems Design

Sector:
Precision Manufacturing



Special Application Projects

CS 350 Cardboard Processing Station

Automating Labour-Intensive, Unsafe Processes

Automatic system development designed for continuous production of cardboard stripping material cut to length. The system replaced a complicated, labour-intensive manual process using hand saws. High-speed, high productivity solution automating a time consuming, unsafe process. Full project design, implementation and on-site commissioning in Sydney, NSW.

Location:
Sydney, NSW

Services:
Turnkey Engineering Systems Design

Sector:
Paper and Recycling



Special Application Projects

SL 360H High-Speed Saw

Solutions for Applications with No Solutions

Special application semi-automatic saw for high-speed cutting of large steel sections. Heavy vehicle manufacturer identified a key production bottleneck at band-saw cutting of a large section. ReconEng was tasked with development of a stand-alone system which could cut the section at five times faster rate or better than existing. The resulting system developed was capable of production cutting 300x100 mm sections in under 90 seconds significantly faster than specification. Full project design, implementation and on-site commissioning in Auckland, NZ.

Location:
Auckland, New Zealand

Services:
Turnkey Engineering Systems Design

Sector:
Heavy Vehicle Manufacturing