Introduction

Access to rail wail signal boxes is often needed for maintenance purposes but difficult for safety reasons
due to working at height. Existing systems that allow access to signal boxes are mostly considered
archaic and outdated. Most commonly used solutions consist of hinge, springs or hydraulic systems that
allow the post to pivot and reach ground level where needed maintenance can be made but they are
considered slow and difficult to use. For that reason in this report a new design solution will be
proposed. The new design consists of a two springs counter balance system that counteract the signal
post weight. The purpose is to present a product that is competitive to these systems and present a final
design. Some of the design features are: easy to use, easy to transport and assemble and can be
operated by a single worker. The report consists of design done using CAD software (SOLIDWORKS) and
was confirmed feasible by calculations, a PDS, concept sketches and a cost estimate of production.

Product Design Specification (PDS)

Item Specification Demand or wish

1. Environment

1.1 Operational temperature ranges from -10o

to 35o C
1.2 Resistance to humidity
1.3 Anti-corrosive
1.4 Able to perform on windy environment
2. Performance

2.1 Lift / lower a load up to ????

2.2 Product perform lift / lower action in 60
seconds
2.3 Operate smoothly and with minimum
vibration
2.4 Product should be portable but with the
option for permanent mounting
2.5 System efficiency must be high
2.6 Safe safety factor
2.7 Product must be light enough to be
portable by on person
3. Aesthetics

3.1 Design must fit in the post base

3.2 Design shows an image of robustness,
reliability, and compactness
4. Durability
4.1 Product is expected to operate outdoors
constantly for 5 years, without failure or
deterioration when maintenance is done
as expected.
4.2 Life performance is assessed by the
performance and environment criteria
outlined before.
4.3 Product will be on the market for 10 years
5. Maintenance

5.1 Bearings lubrication once a month

5.2 Painting renovation every 2 years
5.3 No special tools required
6. Installation

6.1 All pieces installed in less than 120 seconds

6.2 Installation instructions for the product
include an instruction manual with correct
assembly
6.3 Product delivery includes full equipment
and listed parts
6.4 Convenient to handle, easy to install and
undo
7. Testing

7.1 All parts tested in 10% of the units before

releasing in the market
8. Quantity

8.1 700 units per year produced per year

9. Size

9.1 Post shouldn’t be longer than 5000mm of

height
10. Materials

10.1 Designed using environmentally friendly

and recyclable materials
10.2 Lightweight
10.3 Complies with railway signal materials used