Department of Engineering HND Computer Aided Draughting and Design Unit Title: Graded Unit 2 Unit No: F328

35 Candidates Name: Liam McCann Project Title: Miniature Steam Traction Engine

Product Design Specification

1.0 Performance
The product must be to travel on rails with a minimum of jolting and vibration. The product must sit comfortably on the rails and be able to get good traction. This will enable the engine to achieve a more desirable top speed and load pulling capacity. The product must be durable and low maintenance. If the product is designed as a high performance vehicle its durability will suffer. It will also have to have a regular and thorough maintenance schedule. These problems are acceptable however, if the theoretical performance of the vehicle greatly exceeds that of products already on the market.

The product should be able to accelerate at a variable rate and should be designed so that a high top speed or a good load carrying capacity can be achieved, either simultaneously or individually. The product must be able to brake within a safe distance. This performance will be determined by the following table, with consideration given to the steam engines smaller size and mass, and its effect on braking distance.

Braking system Continuous (vacuum) Continuous (vacuum) 3 brake vans 2 brake vans 2 brake vans 1 brake van

Train speed (mph) 45 45 40.9 40.9 45 45

Stopping distance (yards) 410 451 800 631 795 1125 26 30 59 44 55 70

Stopping time (s)

The products boiler must be constructed in such a way to conform to safety standards while maximising its performance. The efficiency of the boiler will be allowed to suffer in the interest of performance.

2.0 Environment
The product will be operating in a primarily outdoors environment so it must be able to cope with this persistently. The product should have a long lifespan. Commercial locomotives had an average working life of 30-40 years, with a max of 70+ years. The product should be properly protected and have adequate facilities for maintenance so that this figure is realistically achievable. The product will also be exposed to a large number of high pressure gases, corrosive and a mixture of large and fine particles during its operation. These may come from a variety of sources, such as the steam, coal dust etc. The product must be able to operate in this environment and continue to function adequately after repeated exposure with the possibility of poor maintenance in between uses.

3.0 Product Life Span

The product is expected to have a potentially indefinite lifespan if properly maintained and used in a way that will not stress the engine. If used in this way it and with replacement parts it will be a viable machine for the next 30/40 years.

If the product is used in a high performance environment it will not be expected to last very long without regular servicing and boiler, drive train, gear and brake overhaul or replacement. Taking formula 1 racing as an example, the engines are almost completely rebuilt after each race. This example shows that while a product has a large potential lifespan, taking it to its max performance repeatedly will dramatically shorten its lifespan.

4.0 Shelf Life

Products and parts will be custom built to order so there will be little need of a large storage space for finished products as all products will be shipped to the customer upon completion of assembly. For those customers who want to build there own engine from a kit supplied by the manufacturer, parts will need to be stored for a reasonable amount of time. On average parts should not need to be stored for more than a year or two, if care is taken to only store those parts that cannot be made rapidly upon receiving a kit order and those that are not used regularly in the standard manufacturer process. For finished products shipping to a customer may require some time so for all shipping ready products one month should be budgeted to complete delivery to the customer.

5.0 Target Costs

As the product will be custom made for each individual in the majority of cases and each customer will have different needs, wants and requirements. For this reason it will be necessary to have a standard cost with listed costs for standard extras and the stipulation not non standard requests will be negotiated.

As a standard cost for a basic model 7500 with the higher end models going for as much as 80,000. These figures have been arrived at after comparative pricing of Kit cars, a similar product, and researching scale trains and steam engine auctions. The cost of storage and distribution should not exceed 5% of total cost. The cost of manufacture should not exceed 35% of total cost. The biggest costs which will be incurred are the specialist labour required for such a product, and the high grade materials used in construction.

6.0 Quantity
100/200 products of the highest grade will be expected for the first year. For limited edition models 25/30 models will be expected to be made in a production run. For all other models whether standard or custom made a more substantial figure of 750/1250 models a year can be expected to be produced. These figures have been compiled by comparing sales of the Bugatti Veyron and cars sold by McLaren. These are both high-end, quality machines and producers of cars and give a good indication of probable sales.

7.0 Maintenance
The final product will require substantial maintenance for proper functioning and peak performance. Also for safety reasons the product will require a regular maintenance schedule to prevent and detect problems before an accident occurs. The product will require regular lubricant of all the axles, horn blocks, bogie pivots and the internal area of the boiler and pipe network. The

crank and cross-pin bearings will also require extension lubrication. Traditionally this is done with tallow or heavy mineral oil. Worsted yarn and oil scented with aniseed was also used for lubrication. If a self-cleaning smoke box is used maintenance will be reduced in that area but regular cleaning of the boiler, piping and exhaust will be required to prevent build up of mineral deposits. These include carbon and other fumes from incompletely burnt fuel, scaling (such as calcium carbonate and other mineral found in water) and rust. These need to be removed to allow good circulation and prevent the engine from over heating. Once a year (more regularly for high performance engines) a full inspection will be carried out. This will require the removal and checking of external fittings, such as the injectors, safety valves and pressure gauge. High-pressure copper pipe work can suffer from work hardening in use and become dangerously brittle: it may be necessary to treat these by annealing before refitting or else they will need to be replaced. A hydraulic pressure test on the boiler and pipe work may also be called for. For normal maintenance of the product a wash-out will suffice. The boiler will be drained and manually inspected by hand. Any mineral deposits will be removed by a pressure washer or a soft metal such as copper, to prevent damage to the inside of the boiler. The fusible plugs must also be inspected for wear or damage; any wear could indicate improper boiler operation. The plugs used to drain the boiler may need to be replaced or recycled depending on the material used. Checking of all the steam pressure indicators can be carried out by slightly heating the boiler and checking the pressure gauge against an external gauge.

8.0 Marketing
The product is too marketed as a luxury good for those interested in the Golden Age of Steam, miniature steam engines, antique equipment. The product will also be marketed at those interested in building their own

kits and the amateur racing community. Many people in the U.S.A are interested in machines which travel quickly in a straight line or gentle curve (Drag Racing, NASCAR or Muscle cars) or can more heavy loads quickly over short distances (Tractor pulling, Lorry pulling etc). It may be possible to market a new sport of high speed personal train racing and other such activities to the right group of people. To promote the product line a special super high speed steam engine may be built to attempt the land-speed record for steam powered locomotives, the land-speed record for locomotives(All classes) and the absolute landspeed record. If any of these aims was accomplished it would mean massive attention would be given to the product which would undoubtedly help sales. To help the product a suitable advertising campaign will be launched to ensure brand recognition. This could include T.V. advertising during F1 racing coverage and other such motorsport activities to attract the racing community. To attract the train enthusiasts adverts can be run during shows about old railways, trains etc. Billboard could also be erected along old train stations that still operate old steam engines.

As this is a luxury good advertising correctly will be important in getting a good reception for the product. This is likely to be expensive initially but the cost of advertising can be absorbed until the product and brand is widely recognised and entrenched. 9.0 Packaging The packaging of the product will be an important part of the delivery process as it is the first thing a customer will see on receipt of their purchase. It is important to make a good first impression to help insure consumer satisfaction and possibly accommodate future purchases.

While the look generated by the packaging will be important it is also important to minimise its weights to help with the cost of shipping. Minimal, high quality packaging will be used to help ensure the right balance. Included in the packaging will be an instruction manual, safety manual and the manufacturers guarantee. A booklet on the history of steam travel, chartings its history from the beginning to the customers purchase will be included as a collectable for train enthusiasts and people for will be interested in locomotive history. The cost of packaging will be a small percentage of the total cost of the product. 10.0 Size and Weight Restrictions
The weight of the product should ideally be kept below 1500Kg unloaded to allow easier shipping and allow easier assembly if delivered in Kit form. Fully-loaded with fuel, load and/or passengers the steam engine will weigh considerably more. The length of the steam engine is relatively unrestricted, other than allowance must be made for the fact that a very long steam engine will have difficulty travelling on a winding track. Also a long steam engine will invariably weigh move than a short one. The width of the engine will be constrained by the gauge of the railway it has to travel along. The steam engine will be required to run on a narrow gauge track. Typically narrow gauge tracks ranger from 2ft (610mm) and between 3ft 6in (1067mm). Technically any gauge lower than the standard gauge of 4ft 8 1/2in (1435mm) is considered narrow gauge. The steam engine will also be constrained by the width of any constructions it will have to travel past or through during its journey. It will be up to the customer, however, to inform the manufacturer of any obstruction to the progress of the steam engine.

11.0 Shipping
The product will be delivered by a combination of road, for local or regional deliveries and rail or ship for longer distance travel. If the customers wishes to pay the extra charges or whos spending have reached a certain level will have their product delivered by air to ensure speedy delivery and customers satisfaction. During delivery the product will be tagged with a chip to allow the customer to track their purchase and help deter theft.

12.0 Manufacturing Processes

The product will require an extensive tool shed with substantial space and facilities for production and testing. The product will require a mixture of riveting tools and the ability to use an arc welder, or oxy-acetylene welding equipment. The facility will also be required to be able to mill steel of some substantial diameter, for the manufacture of the wheel and axles of the locomotive. Furnaces will also be necessary for heat treatment of material and for testing of components. The facility may also need to be able to purify or have access large quantities of purified water. The facility will need to be able to handle quantise of toxic or semi-toxic materials used in the construction and maintenance process.

13.0 Aesthetics
Aesthetics will play an important part of this project, as the look of the product will play as much part as its function in delivering an attractive final product. It may be important to mimic the look of earlier steam trains, such as the Flying Scotsman and The Orient Express to appeal to Locomotive enthusiasts.

The product should have a subdued colour steam, synonymous will classical steam locomotives, rather than a bright colour steam more readily connected with toy steam locomotives. 14.0 Ergonomics
The product should be capable of being operated by anyone in the populated. As a miniature locomotive parts and components will have to be smaller than on a full scale locomotive, but not to a degree that will impede its operation.

15.0 Quality and Reliability

Each product should not have any faults that require a factory overhaul for a period of ten years. The product should be constructed from materials that meet or exceed the specifications for the environments they will be working in as stated in BS8888. For standard steam engines tolerances of .25mm were normal while for diesel locomotives the tolerances were around .0025mm. The product should attempt to have tolerances as fine as normal diesel locomotives.

16.0 Standards and Specifications

All components should adhere to the appropriate British, American and European Standards: ASME, EN13445 for boiler and pressure vessels etc. Plate steel; BS 1449, Din 1624 etc. Insulation, BS EN 14303 etc.

17.0 Safety
The product should attempt to conform to EUs EN 71 or to ISO 8124 which EN 71 is modelled on. The product should include safety devices to prevent catastrophic failure of the boiler or firebox; these can include flues that melt below the temperature of the boiler, fusible plugs, stays etc.

18.0 Testing The products boiler and firebox should be fired to 150% of its standard operating temperature to ensure the product can withstand extreme or improper use. A variety of heat sensors will be placed around the firebox and boiler to ensure the products insulation is functioning properly. The fireboxs fusible plugs may need to be changed for a material with higher melting point during this test. The firebox should be heated to a high temperature to ensure the fusible melt at a lower temperature than the firebox. The pipes that transport the flow of steam should be tested to ensure they can withstand the flow of steam. A comprehensive brake test will be carried out under full and overloaded conditions to test their performance. These tests will be repeated under a variety of different weather conditions to better simulate actual working conditions. The results of these tests will be compared to approved braking distances for locomotives operating today. 19.0 Disposal
All plastic and electrical parts will be clearly marked for disposal and recycling. All metal parts will also be suitable for recycling and disposal if undamaged by steam or chemical corrosion during operation. The flues of the boiler will be unsuitable for recycling due to the extreme wear they undergo during operation. Other parts unsuitable for recycling include the firebox, smoke box, piston heads and other such parts that are exposed regularly to steam, other hot gases or sediments from unfiltered water.

Signature:

(Lecturer)

Approval date: