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Geographe has extensive experience in developing prototypes under agreement with clients using either supplied or contract developed intellectual property. An illustration below is a clear example of the systemised approach we take to successful prototyping.

Custom designed gearbox used for processing in a primary industry with no intellectual property supplied. 

1) Client brief.
The client specified that the gearbox was required to:

• Be driven by a diesel engine, in a very dry and dusty environment.
• Mate directly to the engine to keep the layout compact and reduce alignment issues.
• Have a single input with two counter-rotating output shafts.
• Be simple in its construction with the ultimate aim of becoming a small production run.
• Be robust to operate under full load for long, continuous durations.

2) Prepare preliminary sketches and liaise with client.

• Several iterations of hand sketches were prepared to determine the best layout and shaft centre distances for the gearbox.
• Before finalising the layout, gear load calculations were run to size the gears to ensure they would accommodate the load conditions at the desirable centre distances.
• With gear geometry and shaft centre distances established, our designers looked at how best to construct the gearbox housing. Being a one-off prototype, a fabrication method was selected.
• To enable the client to continue building the rest of the machine, we supplied provisional dimensions of the proposed gearbox.

3) Create 3D model of assembly and present to client.

• With the client’s preliminary criteria now met, a designer accurately modelled each shaft, gear, bearing, housing, fastener and ancillary item using Solidworks.
• From here, each individual component was brought into an assembly model.
• The 3D assembly model enabled the designer to verify fits, clearances and volumes, for example.
• The 3D model was then sent to the client for a final assessment. The client can download a free viewer which once installed, allows him to rotate, dismantle, move and measure the gearbox on his computer screen.

4) Obtain client feedback and suggestions.

• The 3D models sent to the client enable excellent visualisation of what is going to be built.
• In this case, the client requested additional features to be included on the gearbox; some tapped holes to mount a pump, extended input shaft to drive the pump and an additional mounting foot.

5) Implement client’s suggestions into the models.

• The amendments requested by the client were then implemented into the appropriate models and the assembly model was updated.

6) Present updated 3D model to client

• Updated 3D assembly model were sent to the client for final approval.
• The client replied with acceptance of the final design.

7) Obtain client approval and finalise 3D models for all components in the assembly.

• With the client’s approval, the designer proceeded to finalise tolerances, weld preps and production requirements into the 3D models.

8) Create detailed manufacture drawings.

• From the accurately-drawn 3D models, 2D production drawings were then created. These were extracted directly from, and are linked to the 3D models. All section views, details views and isometric views were also created directly off the 3D master models.
• If for any reason, the design needs alteration, the 3D models are modified to reflect the new design parameters. These modifications automatically carry across to the manufacture drawings. This yields more rapid turnaround of development evolution.

9) Manufacture and assembly.

• The production facility then used the 2D drawings to manufacture all the components.
• The gearbox fitting, assembly and test department brought together all manufactured parts and bought-in items (bearings, seals and fasteners) and assembled the gearbox.
• Thanks greatly to advanced 3D modelling software, the gearbox was fitted together with no component rework required.
• The custom gearbox was designed, manufactured and assembled well within the budgeted time allocated.
• The gearbox was tested in house using our zero load test cell and was found to run within acceptable temperature, vibration and sonic ranges.
• The gearbox was delivered to the client for commissioning. Geographe technical personnel attended to ensure any issues or queries were dealt with immediately.

 The above example uses an adaptation of a base framework that is incorporated into every Geographe prototyping project.