Design with Composites

with special reference to

Applications in Indian Railways

Presentation

for

K. Munshi Professor, Emeritus Fellow Industrial Design / Mobility & Vehicle Design IIT Bombay

© K.Munshi

Traditional Composite Materials

Grass Reinforced Mud / Dung Composite Huts

Steel Rienfoced Concrete Bridges

& Buildings

Modern Composite Materials

Plywood Wood +

Phenole formaldehyde resin

14’ square Plywood house

Eames Plywood Chair

Wood based

Composite Materials

Conventionally

application of FRP is

limited to industry -

substitute for steel,

aluminum

profiles, castings,

pipes, fabrications,

panels, drums etc.

FRP –

Consumer

application

limited to

Door panels,

window frames,

Roofing etc.

Beach Cabin in FRP

© K.Munshi Beach Cabin A

The potential of FRPs is immense -

yet to be explored

Creative design

inputs can make all

the difference to make

composites a truly

wonder material

Fiber Reinfoced Plastic (FRPs)

FRP Bridge

Glass

Carbon

Poly propylene

Nylon

Jute

Cotton

Bamboo

Hemp …….

Polyester

Epoxy

Nylons

ABS

Phenol formaldehide

Rubbers ……

Apart from material & process SHAPE is an important factor

Desert

Cooler

Panel

A/C Panel

Wash basin Panel + water tank

Panel with shelves Storage panel Panel with hooks & pegs Panel with built-in seats / tables

Panel with toilet seat & cistern etc.

COMPOSITES -

Designer Materials - can

be tailor-made to have

properties to suit the

application in mind.

‘Industrial design’ can

have a very close connect

with composites - to

realize the immense

potential of composites.

This presentation will

explore this connect with

cases from India

MODULAR PANEL

with Amenities

Powai Lake during Monsoon…… IIT Bombay

IDC IIT Bombay offers a 2-year program M Des Industrial Design

Visual communication

Interaction Design

Animation Design

Mobility & Vehicle Design

The program is meant to develop Knowledge, skill & aptitude to become creative problem solvers and to bring about innovation in the manufacturing and communication industry

© K.Munshi

Micro Battery

Chargers

Solar Rice Cooker

Sanitation Products

Emphasis on socially

relevant projects

© K.Munshi

DESIGN INTEGRATION

Structure & Configuration

Culture & Context

Production & Technology

© K.Munshi

’Design utilisation can be classified into two user

segments. One is design for industry which include big

public and private sector undertakings as well as small

scale sector. This design is already taking place but the

pace at which it is going on, its perceptible and social

impact is limited. The other segment which is fertile for

design inputs is the design for utilities and services which

include transportation, traffic, health, communications etc.

The design inputs in this segment can make perceptible

and immediate impact. The improvements can be seen

quickly and widely. For example Indian Railways can

become biggest receiver of design services if it recognizes

the need for improvement in speeds, carriages, rolling

stock, passenger facilities etc.’

Dynamics of Design & Technology - An Indian Overview, Invited lecture at

International Confrence on Development & Design in South & Southeast Asia,

organised by University of Honk Kong, Honk Kong, Nov.1988

Technology Missions -

Dr. Abdul Kalam Principal Scientific Adviser to Govt. of India

Composites Mission

TIFAC – DST

INDIAN RAILWAY –

RDSO &

Rail Coach Factories

VENDOR –

Hindustan Fibre Glass

Works

IIT BOMBAY –

Ind. Design Centre

Aerospace Engg.

12 Years later…………….

© K.Munshi

© K.Munshi

TIFAC Technology Information Forecasting & Assessment Council

ran

A unique mission –

Advanced Composite Program (ACP)

to promote the use of composites in the country.

Its policy of involving end users and supporting user

industry through easy finance and providing high quality

expertise through consultants ensures success for the

projects of which they have created many examples.

Problems are

Huge!!

What can

designers do?

Design for People

© K.Munshi Modular Toilet for Rail coaches - prototype (exterior)

Case 1

© K.Munshi Modular Toilet for Rail coaches - prototype (interior)

Case 1

© K.Munshi

Modular Toilet for Rail coaches - schematic

Factory built modules

Easy assembly

Maintenance free

Low weight

Long life

Hygienic

Case 1

New Projects:

- Diesel Locomotive Driver’s Cabin

- 3 Tier Sleeper Coach

Indian Railways Increasing appreciation of Design Contribution

for passenger amenities, driver comfort & Safety

….2004 - 05…

© K.Munshi

Case 2

Upper berth –

Descending sequence

1 2

3 4

© K.Munshi

Research in human factors

Case 2

53 c

m

30 c

m

152 cm male

Research in human factors © K.Munshi

Case 2

3 Tier Sleeper Coach - Mock up

© K.Munshi

Case 2

3 Tier Sleeper Coach - Prototype © K.Munshi

Case 2

3 Tier Sleeper Coach - Prototype / Mechanisms

© K.Munshi

Case 2

Integrating human, aesthetic & cultural

factors with materials & Technology

3 Tier Sleeper Coach - Modular Construction

© K.Munshi

Removed

metal support

structures to

reduce weight

& complexity

Integrated FRP modules to

provide overall strength

Case 2

Diesel Loco Driver’s

Cabin

DESIGN OF

DIESEL LOCO DRIVER’S CABIN

for

INDIAN RAILWAYS

Case 3

Diesel Loco Driver’s

Cabin

Case 3

Diesel Loco Driver’s

Cabin

Case 3

Diesel Loco Driver’s

Cabin

Case 3 Investigation of Issues

Diesel Loco Driver’s

Cabin

Case 3

Diesel Loco Driver’s

Cabin

Case 3

Diesel Loco Driver’s

Cabin

DESIGN OF

DIESEL LOCO DRIVER’S CABIN

CONCEPTS

&

STUDY MODELS

Case 3

Diesel Loco Driver’s

Cabin

Most of the panels shall be identical

thereby bringing down variety and hence

cost of tooling and product Diesel Loco Driver’s

Cabin

Case 3

Diesel Loco Driver’s

Cabin

The panels shall be clad on to the existing

structures

Diesel Loco Driver’s

Cabin

Case 3

Diesel Loco Driver’s

Cabin

CONTROL PANEL

1. Present panel seems to have evolved with time and

hence has not integrated all the items into a single

console

2. Proposed panel : integrate all controls and display

into a smaller, more visually and physically

reachable console .

3. All Brakes shifted to console, leg pedal to be part

of console accessible from the seat.

Case 3

Diesel Loco Driver’s

Cabin

Identical console module with duplicate

controls and displays for both users

VIEW FROM OUTSIDE THE WINDOW

Diesel Loco Driver’s

Cabin

Case 3

Diesel Loco Driver’s

Cabin

And displays more readable Control are now more accessible

Reachable…... Diesel Loco Driver’s

Cabin

Case 3

Diesel Loco Driver’s

Cabin

ALTERNTIVE LAYOUT - 1

Integrated consoles oriented so as to give

more room.

Diesel Loco Driver’s

Cabin

Case 3

Diesel Loco Driver’s

Cabin

And also aid access of all consealed

equipment for maintenance

Diesel Loco Driver’s

Cabin

Case 3

Diesel Loco Driver’s

Cabin

Integrated console is made less taller

now will help drivers see each other, communicate and

coordinate better.

Diesel Loco Driver’s

Cabin

Case 3

Diesel Loco Driver’s Cabin

Case 3

CONTROL CONSOLE PROTOTYPE

Diesel Loco Driver’s

Cabin

Case 3

Diesel Loco Driver’s

Cabin

Case 3

Indian Railway

Completed Projects

In FRP

Composite Interiors for Railway

Passenger Coaches

Composite Interiors for Drivers' Cabin

in Diesel Locomotive for Railways

Composite Sky Bus Coaches

FRP Main Door for Passenger & EMU

Coaches

FRP Modular Toilet Units for Railway

Passenger Coaches

Energy Efficient Axial Flow FRP Fans

FRP Gear-Case for Railway

Locomotive

Composites Sleepers for Railway

Girder Bridges

HOUSE BOAT For

Kerala Tourism

© K.Munshi

Research :

Life-style,

Environment,

Ecology & culture

Case 4

© K.Munshi

Case 4

1st Prototype

Luxury Houseboat for Kerala Tourism - Exterior

4.5 M

X

25 M

3.5 M

Luxury Houseboat for Kerala Tourism – Prototype Building

© K.Munshi

Case 4

Luxury Houseboat for Kerala Tourism - Interior

© K.Munshi

Case 4

Luxury Houseboat for Kerala Tourism

Modular Construction- 5 Modules for super structure

© K.Munshi

FRP Hull & Super-structure

Self-supporting interlocking

modules (no metal supports)

Factory built panels

Expandable system

Easy, Fast & Economic assembly

Case 4

Frangible Cabin in FRP For Bangalore

International Airport

© K.Munshi

……. With built-in weakness

Case 5

Frangible Cabin in FRP For Bangalore

International Airport

Modeling & Analysis to ensure it collapses

on impact with aircraft

© K.Munshi

Case 5

Designed to Collapse

Case 6

Single unified

Body design in FRP

integrating

Styling,

Ergonomics,

Engineering

All the components

are mounted on the

load-bearing FRP

body

Electric Vehicle

© K.Munshi

No metal chassis

Light weight

Vibration & Fatigue

resistance

www.ctechlab.com

Mentoring for new product development, leading teams of

developers. Hand-holding till the prototypes are made

Introducing Methodologies & product development strategies (analytical

tools, creativity tools etc.) to achieve high certainty of success

Motivating & Challenging for higher levels of creativity

Monitoring product development process to create products for

high productivity of design effort

4 M Strategy …… ????

Methodology

Mentoring

Monitoring

Motivating

,

Innovation

Development

Company

……..creative design strategies, appropriate engineering

concepts, combined with humanistic approach help

develop innovative products, which also address the

concerns of the users effectively and make these products

successful in the market place …..

The power of ‘holistic & integrated

design’ approach can unleash the great

potential of Composites as a material

and be the driver for its future growth….

……..creative design strategies, appropriate engineering

concepts, combined with humanistic approach help

develop innovative products, which also address the

concerns of the users effectively and make these products

successful in the market place …..

The power of ‘holistic & integrated

design’ approach can unleash the great

potential of Composites as a material

and be the driver for its future growth….

Thank You