Header
Prologue
COMPANY
Qualcomm
DESCRIPTION
DEVELOP INDUSTRY FIRST POLE MOUNT RBS
SITUATION
Create a design for a small form factor, light-weight, pole/wall mounted mobile phone base station.
OBSTACLES
Existing base stations were large, ground based, cabinets.
ACTIONS
RESULTS
COMPANY
StorageTek
DESCRIPTION
ADAPT CERAMIC TAPE GUIDES TO NEW DESIGN
SITUATION
OBSTACLES
ACTIONS
RESULTS
COMPANY
StorageTek
DESCRIPTION
DEVELOP SERIES OF MOLDED DOOR INSERTS
SITUATION
As an overall modular approach to various tape drive cabinets a decision was made to minimize the number of door panels by using insertable tools.
OBSTACLES
Make the panel installation tool-less. create inserts in the tools to lower the overall cost of tooling. Create panels that are robust, durable, allow proper ventilation and are easy to assemble.
ACTIONS
Designed in many snap fits to aid in assembly. Panel variations were introduced via a series of tool inserts. Glass-filled Polycarbonate (Lexan) foam was chosen as the material giving the most desirable attributes per the design intent.
RESULTS
Panel performed as designed. The overall corporate look of a "molded" door was maintained. Assembly was simplified. DFM requirements were met. Cost was minimized. Product was very successful.
COMPANY
StorageTek
DESCRIPTION
CONVERT MOLDED CABINET DOOR TO SHEET METAL
SITUATION
Current design intent was for a molded plastic one-piece door. Door size (~60" X 24") was causing many fabrication issues and delays. I was given the task to investigate an alternative design that would meet cost, schedule and product specification requirements.
OBSTACLES
Much time had been expended already with no progress. Injection molding tool was enormous and extremely costly with no guarantee of success. A plastic door, if molded, would still not meet EMI specs.
ACTIONS
Developed a sheet metal door out of thin gauge steel with reinforcing members as required. Worked closely with industrial design firm and fabricator to insure that door would satisfy the corporate look and feel. Door was indistinguishable from a molded door when completed.
RESULTS
Door design proved to be very producible, light weight and cost effective. Corporate look was maintained. After review, other heavier variations of cabinet doors were converted to my light weight design. A patent was issued for our tape drive cabinet design. This product (Timberline) proved to be very successful for StorageTek and a source of strong revenue.
COMPANY
Ericsson
DESCRIPTION
2.5 U "POPEYE" POWER SUBRACK
SITUATION
An RBS design that we were working on required a different form factor that the "std" configurations that Ericsson offered.
OBSTACLES
Instead of 9 units mounted vertically 2.5U would only accommodate 6 units (2 rows of 3). All of the power bus bars would have to be redesigned and reconfigured.
ACTIONS
An attempt was made to reuse as much of the original "std" design as possible. Some of the sheet metal was able to track the original intent, but the entire power and gnd bus system had to be redesigned.
RESULTS
A 2.5U sub-rack was designed and built successfully. Much of the bus bar system was redesigned with an emphasis on modularity and economy of scale.
COMPANY
Ericsson
DESCRIPTION
ADVANCED RENDERING PRESENTATION
SITUATION
I was asked by the lead sys admin for all Pro/E MCAD assets if I would be willing to put together some training materials on Advanced Rendering for the annual key-user meeting in Europe.
OBSTACLES
Never done anything like this for such a large audience. A bit apprehensive when it comes to speaking in front of groups. Material only existed in my head. No illustrations existed.
ACTIONS
Put my ideas and acquired knowledge down into two separate documents. A Power Point presentation and a How-To online guide for future reference. Much experimentation and generation of graphic images to illustrate the concepts.
RESULTS
Pretty nervous! Delivered the 45 minute presentation to two separate groups. Also gave a high level overview of the How-To guide and where to access that. All materials and presentations were well received.
COMPANY
Ericsson
DESCRIPTION
ODE FILTER SCREENS
SITUATION
Field request from a Pacific Northwest provider to provide field installable screens on their outdoor enclosures. The existing vent slots were too large and the fans were getting plugged with cottonwood seeds affecting performance.
OBSTACLES
Identify an appropriate screen fabric. investigate possible methods for securely mounting in the field without powering down the cell sites. Keep the cost low.
ACTIONS
Determined the proper opening size of a stainless mesh fabric. Identified a supplier. Worked with shop in Texas to understand best fabrication methods required to produce a professional looking screen. Did several design studies to come up with a secure technique for mounting various sizes of screen.
RESULTS
Prototype parts were turned in a matter of weeks and successfully installed in the field.
COMPANY
Ericsson
DESCRIPTION
RRUS MOUNTING
SITUATION
Request to determine if 3 Remote Radios could be mounted in a 23" rack for an event at Cowboy Stadium.
OBSTACLES
Each radio weighed approximately 60 lbs. Never intended to mount in a rack. Installation would be awkward and potentially dangerous for field installers. 23" rack is non standard.
ACTIONS
Determine appropriate gauge of sheet metal mounting plate. Added features to help register and support radio unit during install.
RESULTS
Blah
COMPANY
Ericsson
DESCRIPTION
QUICLINK
SITUATION
Design a man-portable remote base station for disaster relief and the military.
OBSTACLES
Keep weight under 100 lbs, unit must withstand dust storms, wind driven rain, zone 4 seismic and be able to deploy on short notice.
ACTIONS
Struggle... Several configurations and design revisions. Worked with factory in Sweden to eliminate producibility and quality issues. Sealing (wind driven rain) was an on-going issue until late in the design. Many attempts to reliably convey proper sealing techniques.
RESULTS
Ultimately a reliable and producible approach to sealing was achieved. This required a lot of discussions and testing with the the factory's involvement. Upon a successful test demonstration the product was transferred to a product unit in Hungary.
COMPANY
Ericsson
DESCRIPTION
PUSH-TO-TALK PHONE TESTER
SITUATION
Customer requires a rack mounted (indoor) test bay allowing them to test 64 mobile phone handsets per rack.
OBSTACLES
Rack requires; Phone shelves, power supplies, cooling fans, PC, monitor, keyboard/mouse, port server(s), Ethernet hub(s).
ACTIONS
Blah, blah, blah.
RESULTS
Customer very pleased, increased their original order after first article delivery.
COMPANY
Ericsson
DESCRIPTION
ODE 6201 OUTDOOR ENCLOSURE
SITUATION
Customer wishes to replace existing outdoor enclosure with upgraded network functionality.
OBSTACLES
Fixed footprint, existing outdoor enclosures too big.
ACTIONS
Work with 3rd party vendor to design outdoor "over enclosure", weatherproof, self contained thermal management system, added CDMA compatibility.
RESULTS
Enclosure was being readied for environmental and regulatory testing at time of office shutdown.
COMPANY
Ericsson
DESCRIPTION
MOBILE ANTENNA
SITUATION
Provider requires a portable antenna that can be easily mounted to a van, driven to a remote site and quickly deployed.
OBSTACLES
Vehicle type, mounting geometry, secure for travel, no. of antennas, antenna geometry, antenna location and orientation, multiple configurations.
ACTIONS
Designed a folding mast capable of mounting to a standard trailer hitch, 3 antennas mounted vertically to a 18' mast, also designed a 4 antenna mast that allowed van to drive around with mast deployed.
RESULTS
Travelled to fabrication shop in Texas to oversee part fabrication and test fit. Then travelled to Minnesota to manage build of 6 systems. Customer very happy.
COMPANY
Ericsson
DESCRIPTION
LTE/DAS
SITUATION
Blah
OBSTACLES
Blah
ACTIONS
Blah
RESULTS
Blah
COMPANY
Ericsson
DESCRIPTION
JOEY
SITUATION
Blah
OBSTACLES
Blah
ACTIONS
Blah
RESULTS
Blah
COMPANY
Ericsson
DESCRIPTION
FLEX27
SITUATION
Customer request to mount 3 Remote Radio Units into an existing cabinet (19" rack) in the field hoping to avoid the additional expense and schedule slip that starting over with the permit process would cause. Previous contractor had failed to deliver usable hardware.
OBSTACLES
Units would not fit in cabinet (19" rack) using any traditional manner. Too tall to mount vertically, too wide if laid flat and stacked. Access for cables and air circulation for fans had to be allowed for. There was a very narrow window (short schedule) to get units into the field.
ACTIONS
Quite a puzzle. Many different orientations and alignments were tried in the model. Eventually a fairly modular and installation friendly assembly was settled upon. A quick-turn prototype shop was chosen and delivered parts within a week. A late change to the enclosure configuration caused a small delay. Solution was identified quickly and parts were reworked accordingly.
RESULTS
Customer met their deadline allowing them to bring additional subscribers online securing their revenue projections.
COMPANY
Ericsson
DESCRIPTION
19" RACK ADAPTOR
SITUATION
Customer requested the flexibility to allow non-standard mounting of units into a 19" rack.
OBSTACLES
Allow units to be mounted when no mounting holes are present. Minimize impact to air flow and cabling.
ACTIONS
Developed a machined Al block with counter bored thru holes matching EIA-310D standard spacing. Block also carried a second set of Heli-Coil reinforced tapped holes for the mounting of customer units.
RESULTS
Customer was able to proceed with unit mounting of his choice with only a slight forward offset to mounted units, still well within acceptable parameters.
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