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In the summer of 2020 Hallam began to work with Vimpex Limited, a highly regarded major specialist UK supplier of fire detection, alarm and evacuation solutions. After careful analysis of functional requirements, including consistency of resonance and tone, Hallam was asked to manufacture new tooling for Vimpex’s fire alarm housings. The tooling has been carefully designed to create an even flow pattern of aluminium to the tool and eliminate porosity within the cast housings. Hallam now casts, machines and powder coats the housings using a specially configured aluminium alloy and architectural powders for resilience in all environments.

The bell remains the most commonly used alarm for fire evacuation systems. Recognising this, Vimpex has continued to innovate with their all-aluminium range of fire alarm bells. Five bells make up the range of 150 mm (6˝) and 200 mm (8˝) internal and external units. Being of aluminium construction, Vimpex bells have a very high volume output matched with extremely low power consumption – just 11 mA for the 150 mm internal. The specially designed weatherproof bells have an aluminium back box giving either single or double threaded entry for maximum flexibility in installation. This is supplied as a full fixing kit with gasket and screws. As with the Vimpex sounder range, all bells can be supplied branded with a company logo.

See more at the Vimpex site: www.vimpex.co.uk

In 2019 Hallam was contacted by a leading UK manufacturer of ocean-going yachts for global sporting and leisure markets seeking new designs and more efficient methods of manufacture for the portlights (windows) in the hulls of the yachts.

The manufacturer hoped that the high-pressure diecasting method would allow the portlights to be manufactured in one piece rather than fabricated. However, this also involved:–

1. A change of raw material from fabrication alloys to casting alloys and selection and testing of an appropriate alloy.
2. Complete mechanical redesign of the portlight range to make the designs consistent with the new manufacturing process.
3. Extensive testing of finishing treatments applicable to the casting alloy selected.

In particular, the new materials and finishing treatments would need to withstand the effects of extremely harsh oceanic environments and prolonged exposure to the intense UV radiation (sunlight) typically found in leisure yacht mooring locations.

The re-design of the portlight range was particularly challenging as the design had to allow for flush fitting to contoured hulls as well as fixing, sealing and anchorage points for internal features within the cabins. The raw material was chosen from a portfolio developed during Hallam’s experiments with casting alloys for traffic and roadside environments where saltwater resistance in harsh environments over many years was a key requirement.

External testing houses were used to simulate the finished products’ exposure to saltwater and extreme mechanical forces as well as 10 years constant exposure to Caribbean sunshine. CIELAB methodology was utilised for colour testing after simulated exposure to UV radiation.

The portlights are now manufactured as a complete unit by Hallam across a wide range of sizes and configurations removing the need for fabrication processes.   

Description

During 2020 project work on new products with customers has continued despite the pandemic. Some of the projects are outlined below. 

Welding testing – aluminium alloys

This unusual project involved working with a UK-based testing house to establish an experimental framework for the analysis of the effects of TIG and MIG welding on cast aluminium, in accordance with ISO 10042. Hallam’s input was to interpret the metallurgical requirements of the ISO standard and provide test plates in the form prescribed made from a raw material compliant with the definition in the standard.

The welding tests were undertaken by the testing house and provided a useful analysis of the effects of the welding processes on the test plates including liquation cracking, distortion and deformation, chemical effects including oxidisation as well as the effects on mechanical properties. The results of the study were added to the testing house’s technical library.

As a result of a direct recommendation, Hallam has gone on to supply other types of metallurgical samples for microscopic testing to clients of the testing house, including a major global manufacturer of optical products and optoelectronic systems. 

Plant protection systems – expanded metal processing.

This interesting project involved experimenting with a process new to Hallam to produce expanded metal sheets which were then edged and test formed using a variety of methods to create curved protective sheets for use in domestic gardens to protect crops from rabbits, pigeons and other garden pests. Following further research, the curved sheets were powder coated and placed over rows of garden vegetables including salad crops. Hallam staff were involved in the experimental trials.

A surprising array of technical issues arose during the trialling including material choice, form and gauge issues for optimum mechanical properties, dimensional issues, handling safety and robustness of the system generally. However, the trials were successful and the product is expected to become available in  2021.

Other projects

Other projects begun in 2020 include the development of a new type of shop floor data capture stylus for the food processing industry, involving research into food safe polymer materials as well as design issues. As well as having good functionality in the food environment the stylus must have metallic components so as to be easily detectable by scanners if dropped into food mixes on production lines.

Hallam is also continuing to work with a major UK manufacturer of modular balcony systems for the construction sector, in developing anchorage systems for furniture on the balconies.

Description

This interesting project involved designing and prototyping a compression driver housing (a “tweeter” –higher frequency sound range-in this case) to minimise sound distortion in a leading edge high end PA system product. The product required was not simply a mechanical chassis for mounting loudspeaker components, but a major integral element of the tweeter designed to channel and optimise sound reproduction.

Challenge

Major challenges were the development of an appropriate non-ferrous alloy (because of the speaker magnets) with the required ground breaking acoustic characteristics. However mechanical CAD systems cannot normally be used for resonance simulation. Design and positioning had to be within exact tolerances to maintain the sealed integrity of the speaker housing.

Solution

The absence of simulation software meant that a number of physical prototypes of the component had to be made using different metal alloys, and frequency response and resonance measured with specialist equipment.

Each prototype was incorporated into a complete speaker housing to ensure functionality

Summary

The complete product was marketed successfully globally in 2016.

Hallam first worked with CMD to design and manufacture the hugely successful “Cygnus” flat screen monitor arm and most recently has helped CMD to develop the “Reach” monitor arm variant. These complex projects involved the design of an articulating and positionable assembly of pressure cast aluminium parts, aluminium extrusion, laser cut steel plastic injection mouldings and a laser cut steel computer monitor mounting plate.  Assembly options allow the product to be configured to support up to three computer monitors from desktop or wall mounted anchorage points.

The functionality requirements for these products were wide-ranging and presented a considerable technical design challenge.

Market driven, the products had to offer:-

• Flexible and diverse mounting options within differing office architectures
• Safe height and angle positioning under user control in situ
• Accommodation of a wide range of monitor designs, although some standardisation of mounting point design features has emerged within the industry.

In designing and simulating the assembly CAD models, the design for manufacture (DFM) elements of the projects were particularly challenging. In particular, there were uncertainties around:-

• Tolerancing, across a range of diverse materials
• Dimensional allowances for interference and push fit elements of the assembly
• Material resilience to the longer term effects of positioning adjustment

Research at the DFM stage for the basic products and variants was particular intensive for this project.  Research and simulation elements included:-

• Analysis of polymer specifications and attributes and selection of best suited
• Research into the load bearing capacities of alternative materials and analysis of CAD assembly models in this respect
• Repeated prototyping to ensure functionality would be as envisaged

The products are offered in many variants allowing optimum flexibility for alternative office layouts and alternative desking and cabling solutions.

Full details of the product range can be seen at:
https://www.cmd-ltd.com/ergo-solutions

In 2015 Hallam began to work with Sheffield-based LED lighting specialist Constellation Lighting in developing a state-of-the-art modular LED lighting system for industrial and commercial markets. The project began with the commissioning of concept models from designers at the Advanced Manufacturing Research Centre (AMRC) University of Sheffield.

Throughout 2016 Hallam developed a series of prototypes based on the AMRC concepts incorporating variations in power transfer systems, LED board and lens design (both commissioned externally) as well as mechanical design variations around the module housing and heatsink.

The product was launched initially in 2017 and incorporates the following key features:-

• 7700 lumens at 61w from an individual module
• Specially commissioned LED board design and manufacture
• Up to 9 modules can be connected, providing stadium-level lighting
• LINKS is an AC system; separate drivers are not needed.
• Each module weighs only 1.9kg
• Heatsink design ensures very low thermal resistance
• Has ATEX, IEC/EN for European markets and UL approvals for America.
   
  This has been an exciting project for both companies leading to the development of a new LED board with an exceptional (market leading) light output to power consumption ratio, housed in bespoke individual modules connected by an innovative patented power transfer system. Full details of the product range can be seen at:-
   
  http://www.constellationlighting.com/lighting-products/links-led

Description

The aim of this project was to create a robust and resilient housing to accommodate an LED unit with a 12 hour battery to provide back up where mains supplies were interrupted

Challenge

One of the key target markets for this product was the London Underground system and similar systems worldwide. The design of the housing, including the hinging mechanism for the gear tray (essentially a “lid” allowing maintenance access) had to be determined by Hallam.

As part of the design for the housing, the power cable routing system also had to be specified and prototyped by Hallam.

Solution

After design, simulation and several prototypes had been made, a hinging mechanism using some of the knowledge derived from other projects was found to be satisfactory. That hinging mechanism allowed repeated accurate placement of the two parts of the unit together. The hinges worked accurately and the system included sealing systems utilising the same carefully researched adhesive derived from pedestrian and traffic control system projects.

A completely new solution was found for the power cable routing features within the housing. The requirement was to provide an option for the installer either to install individual units or connect a number in series – either one or two routes into the unit, for the power cable, might be needed.

Hallam’s solution was to design and provide two “pop out” sections within the outer wall casing, one on either side, allowing either series or individual wiring. The development of the required functionality in volume production for the pop out sections proved to be a considerable technical challenge but Hallam was successful in achieving this.

Summary

The product has again proved to be successful and has been installed in a variety of environments including the London Underground system, sports halls, aeroplane hangars and a wide range of domestic, commercial and industrial buildings.

Description

Pelican crossings have been in existence for many years but the aim of this project was to create a product to be aimed at the fiercely competitive European market. The pricing of the product was crucial but also the unit had to be developed so that it could achieve a high IP or waterproofing rating which is a significant area of weakness on competitor products.

Challenge

This project involved housing a new PCB within a two-section sealed housing with a new hinging system consistent with the IP (waterproofing) rating required for the complete housing. It was very important to achieve a high IP rating because other products traditionally in the market have suffered from water ingress and thus unreliability.

As well as designing and manufacturing the housing Hallam had to find gaskets and sealing systems to achieve the high IP ratings desired. The technical challenges were made particularly difficult by the cost constraints because of the competitive markets into which the product was aimed.

Solution

Design for manufacture of the internal features required for mounting the new PCB represented an almost routine challenge but the hinging system requirements proved to be difficult to achieve. A number of models, simulations and prototypes were required until a final successful hinging system was developed.

The prototypes were constructed so that the operation of the hinge effectively placed the top and bottom part of the control box into an exact alignment onto the seals and gaskets. This would mean that the device was waterproof when the cover was closed and remained waterproof after it had been opened to service it. The hinging system therefore needed to repeat accurately and keep the top and bottom part in precise location on the seals and gasket to retain the waterproofing capability.

The hinges also involved utilising stainless steel pins and again it was essential to ensure that they stayed accurately located and therefore did not allow disturbance of the alignment of the top and bottom part of the control box.

The sealing system also required research into state-of-the-art gasket materials and special adhesives suitable for attaching the gaskets to the polyesters of the architectural-powder coated housing body.

Summary

This product has proved to be extremely successful and since this system was developed, several other similar products have been designed or redesigned with similar levels of success.

Description

This product was a new concept in LED-based “urban space” outdoor lighting provision for the public sector.

Challenge

For this new concept, the position of the main body of the lighting assembly needed to be variable via a range of mounting brackets and mounting assemblies. The marketing aim was for lighting system to be useable either as a traditional mid-level street light or at a lower level, angled to provide lighting to street frontages or other public urban areas where security or safety had become a concern.

There was also a technical challenge in that a new leading edge LED board had been incorporated in the lighting design and heat sink calculations for heat dispersal were required (i.e. the minimum surface area of the main body heat sink fins needed to be calculated).

Solution

A novel ratcheting system was developed by Hallam to allow the main body housing to have variable positioning for a range of post top and the side fixing mounting brackets. Small teeth built into the main body and mounting brackets allowing a substantial range of positional adjustment in situ.

The combination of different types of mounting bracket and the ratcheting system gave the variability in positioning required by Hallam’s customer and also the ultimate users of the lighting for public sector applications.

Summary

The product has proved to be extremely successful and the system since April 2015 has been selling well to local authorities and other public sector authorities. The IP rights for the heat sink calculator vest with Hallam and the calculator continues to be used successfully by the company on lighting projects.