Engineering Design Services
Bespoke Engineering Design Solutions
At Allan J Hargreaves Plant Engineers, we provide professional engineering design services tailored to the rail plant, civils plant, specialist plant and industrial sectors. Combining extensive industry experience with advanced 3D CAD technology, we develop innovative, practical, and safe engineering solutions that improve performance, reduce operational risk, all while meeting regulatory requirements.
Whether you require a completely new design, modifications to existing equipment, or support with a specialist engineering project, our experienced team delivers cost-effective solutions from initial concept through to implementation.
Advanced 3D Design and Engineering Analysis
Using industry-leading 3D design software, we create detailed engineering models that allow clients to visualise solutions before manufacture and installation. This approach helps identify potential challenges at an early stage in the project lifecycle, reducing costs, minimising downtime, and improving overall project efficiency and outcomes.
Our design capability includes:
- Full 3D CAD design and modelling
- Concept development and design optimisation
- Detailed manufacturing drawings
- Reverse engineering of existing equipment
- Design validation and risk reduction
- Mechanical system and component design
- Structural assessments and verification
To further enhance design reliability, we can carry out Finite Element Analysis (FEA) to evaluate structural performance under operational loads. This enables us to identify stress concentrations, improve structural integrity, and ensure equipment performs safely and efficiently in demanding environments.
Proven Engineering Solutions
Our engineering team has successfully delivered a wide range of bespoke projects across the rail and industrial sectors. Examples include:
- Height limitation systems
- Slew limitation systems
- RCI / RCL / SLI load limitation systems (preventing machines from tipping over)
- Boom suspension (ride control) for wheeled excavators
- Weighing systems
- Camera systems
- Hybrid machine conversions (Diesel Electric Hybrid Conversions)
- Electric mobility packs for Plug in electric machines
- Full electric machine conversions
- Boom safety valves (load hold valves)
- Installation of additional hydraulic services or hydraulic diverter systems
- Telematics and connected machinery
- Telescopic arm conversions
- Compressor systems
Direct Rail Wheel Braking Systems
Railway Excavators and RRV's must now have a direct rail wheel braking system installed to reduce the risk of Runaway when used on gradients, Network Rail mandated the installation of Direct Rail Wheel braking around 2014, AJH were one of the pioneers in developing a failsafe braking system for the type 9b Railway excavator, otherwise referred to as two-way excavators or RRV's in more general terms. AJH have retrofitted over 400 machines with failsafe brakes to meet Network Rail requirements, the requirement calls for machines to be equipped with independent parking and service brakes to meet specified deceleration requirements for service brakes and gradient holding requirements for the parking brakes. A SAHR, Spring Applied Hydraulic Release brake is used as the parking brake whilst a hydraulic service brake is used when the machine is travelling dynamically and in some applications used as a digging brake. AJH have a number of solutions available and can consult on the optimum design solution working from a portfolio of existing braking systems, which also include wet brake, multidisc and drum brake solutions in addition to standard disc brakes, for hydrostatic machines AJH also specialise in hydraulic oil management and braking control systems (hydrostatic braking).
ALO Slew Limitation Systems
From basic mechanical slew limitation, hybrid mechanical electrical control, to PLd, SIL2 high performance movement limitation systems we have been involved with them all. Approving a machine for working Any Line Open comes with a host of considerations and technical requirements to meet depending on distance to the running line, foul points and the type of machine in operation, the ALO requirements are defined in RIS-1530-PLT & M&EE COP0032. If you have a particular problem to solve we are here to help.
OLE Height Limitation Systems
Working or Travelling under Live Overhead Lines, or catenary, poses some very specific risks, the benefits can be increased possession time due to negating the need to take an isolation at the beginning of the shift and reinstate following the shift. The OLE runs at 25kV (AC) and provides power to the power car (train) via a pantograph during normal use. During maintenance work, normally carried out through the night excavators and other RRV's may be required to travel down the line and carry out maintenance work. Specially designed height limitation systems are used which are defined as a "High Performance Movement Limiting Device" in RIS-1530-PLT, the control systems are required to meet SIL 2 for software and the control architecture must comply with BS EN 13849 PLd.
Safety Engineering and Risk Assessment
Safety is a critical element of every design project. Alongside our mechanical and structural design services, we provide specialist engineering assessments to support compliance and risk management requirements.
Our services include:
- Failure Mode and Effects Analysis (FMEA)
- Machinery risk assessments
- Functional safety assessments
- Safety-related control system design
- Risk reduction strategies
- Technical documentation and compliance support
We can assess and design Safety-Related Parts of Control Systems (SRP/CS) in accordance with BS EN ISO 13849, helping clients achieve the required performance levels while ensuring machinery and systems operate safely and reliably.
Why Choose AJH Plant Engineers?
- Extensive experience in rail, plant and industrial engineering
- Bespoke solutions tailored to your operational needs
- Advanced 3D CAD and FEA capabilities
- Strong focus on safety, compliance and risk reduction
- Practical engineering support from concept to completion
- Proven track record delivering specialist engineering projects
Discuss Your Project
If you require a bespoke engineering design solution, machine safety assessment, FEA study, or technical consultancy, contact Allan J Hargreaves Plant Engineers today. Our experienced engineering team will work closely with you to develop a safe, practical, and cost-effective solution tailored to your operational requirements.