This case study delves into the inception, challenges, and eventual success of a project, which aimed to create a rotation jig to replace 10 damaged plywood concept test fixtures. The primary motivation for this project was the need to enhance safety standards and provide durable test rigs for wind turbine components’ rotation from horizontal to vertical planes.
MedTec initiated this project due to a client requirement for a new conceptual design due to the existing plywood fixtures being insufficiently sturdy for testing purposes. We then embarked on a comprehensive research and development phase running numerous possible design solutions whilst hosting regular design reviews with our client until we had agreed on a design to take through to detail design.
The project aimed to design portable yet secure test rigs that could accommodate two types of composite web profiles: the existing one and a new, unique profile. Safety and ease of use for operators were paramount, with a focus on eradicating health and safety issues associated with the current fixtures.
During our design and development phase and to meet the project’s goals, we conducted numerous tests and trials, experimenting with various frame designs, materials, and sizes. Storage solutions were devised to ensure the secure storage of rotation items when not in use. A CAD model was generated to visualise space constraints and facilitate the final design.
Modularity was a key consideration to improve production efficiency and spare part accessibility. The rotation section was split into two parts: a rotating part and a clamping part. Extensive CAD simulations and schematics guided the design process to ensure smooth transitions and uniformity of components.
Further testing involved Finite Element Analysis (FEA) to check for clash testing and validate load paths and freedom of movement requirements. Frame loading simulations led to necessary design modifications. Ultimately, an aluminium frame with deployable casters was chosen for its weight-to-strength ratio.
Throughout the project, we encountered substantial technical uncertainties. However, through persistent testing and trialling, these challenges were overcome. This led to the finalisation of the design, which has been successfully manufactured, installed, and is currently in use.
This project has not only met the client’s requirements but has also resulted in a wealth of firsthand industry knowledge. The team at MedTec as well as our client are highly satisfied with the outcome, with positive feedback after several months of successful use. As a testament to the project’s success, MedTec has been approached to apply the knowledge gained to create a third web for rotation, which is currently in use at the same facility.
In conclusion our journey to design and develop a rotation jig exemplifies the importance of thorough research, testing, and adaptability in meeting complex engineering challenges. This case study serves as a valuable resource for future projects with similar requirements, showcasing the benefits of innovation, technical expertise, and client collaboration.
