Context & users

Field teams needed a compact, vehicle-mounted scanning system that remains robust under vibration, temperature, dust, and service cycles. The mechanical design had to protect critical components, integrate cleanly with the chassis envelope, be maintainable in the field, while maintaining imaging quality requirements to pass UAT.

Requirements / constraints

• Tight package within vehicle envelope; defined keep-outs and service clearances

• Weight and center of gravity requirements to meet Ford Body Builders Guidelines

• Vibration/impact tolerance; thermal basics; ingress mitigation at interfaces

• Tool-accessible fasteners; repeatable service procedures

• Manufacturable brackets/panels; clear drawings and traceable documentation

• Bench → on-vehicle validation testing with explicit pass/fail criteria

Solution architecture (sanitized)

• Structures: composite panels + machined/sheet-metal brackets with stiff load paths

• Isolation & interfaces: compliant mounts where needed; strain relief and protected cable routing/ducting

• Service design: standardized fasteners, captive hardware, and access panels with defined sequences

• Documentation: CAD with GD&T; multi-level BOMs in PLM (Arena); assembly/inspection checklists

Engineering highlights

• Stress/vibration analysis: FEA to identify hot spots and tune bracket geometries; modal checks to avoid resonance

• Tolerance stacks: datum strategy and clearance studies so parts assemble first-time in production

• Fixtures: bench fixtures for pre-install validation; alignment jigs to speed on-vehicle assembly

• Thermal/ingress: passive paths for heat; seals/gaskets at likely dust/water ingress points

Build & validation testing

• Bench: subsystem fit checks; torque procedures; fixture-based shake/impact stand-ins; verify cable strain relief and connectors

• On-vehicle shakedown: road-equivalent vibration and thermal soak; periodic inspection for loosened hardware or rub points

• Traceability: test matrix with pass/fail notes; issue log → design revisions → retest

Results (sanitized / normalized)

• Deployed to multiple field installs with stable mounts and clean service access

• Assembly time reduced via standardized hardware and clear sequencing

• No structural failures observed across shakedown runs; connectors and cable paths remained protected

• Design transfer package delivered with drawings, BOMs, and fixture procedures (suitable for suppliers)

What I’d improve next

• Convert frequent brackets to single-tooling families; add captive nuts where still loose

• Formalize environmental ingress tests (dust/water) and long-duration vibration endurance

• Expand serviceability: tool-less covers in high-touch areas; quick-disconnect harness options