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
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
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
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
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
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
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
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
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
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 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