®

PASSION FOR PERFECTION IN

DESIGN AND MANUFACTURE

portfo li o by

radu bojan
p r i n c i pa l e n g i n e e r & f o u n d e r
 We offer customized and complete design services by carefully planning and monitoring
project stages and engineer’s workload to meet specifications and to achieve the highest
level of detail in the allocated timeframe. Our focus is on the final product and we believe
® in simple and robust designs that will ensure quality, reduce costs and increase productivity.
Our main activity is in Automotive and Motorcycle Industry and
we have experience in the following engineering stages:
As a support to our designs we are capable to employ and
manufacture parts for prototyping, functional testing, one-off
projects up to small production volumes. Motorcycle styling bucks
and initial testing bikes, assembly work stations and equipment,
jigs and fixtures are a few examples of projects that we can deliver
as part of the complete engineering services we offer,
from design to manufacture.

Benchmark evaluation, explore ideas and investigate engineering feasibility for the preferred
Concept solution, patent search, general 3D CAD layout and provisional packaging, first mock-up using
prototype parts as a functional test, identify areas that need changes and further investigation.

Styling For projects that require styling input engineering schemes will progress in parallel with
support styling sketches and clay models liaising with the styling house up to the detailing stage.

Timing plan and budget control, component specification, surfacing and 3D CAD modelling,
Scheming calculations, FEA work, clearance checks, tolerance stacks, scheme/assembly drawings to
highlight parts interaction.

Detailing Design reviews for sign-off, drawings release.

Testing First prototypes are made and tested using as many off tool parts as possible. Functionality
support and durability is monitored and evaluated to meet specifications.

Trial Build & We like to follow our designs into production stage and we give support for any
Production requirements arising.
support

DESIGN services MANUFACTURING services

 PROJECt DESIGNED
tiger explorer COMPONENTS triumph
motorcycles
Luggage Rack &
TIGER EXPLORER is among Pannier Rails
the best selling models of
the British company Headstock Infill &
TRIUMPH Motorcycles and Fuel tank Centre Piece
Award Winner in 2012 for Under seat packaging Rad Cowls &
of Electrical Components, Radiator Infills
Adventure class. Accessory U-Lock & Alarm
Engineering responsibility
for designed Packages &
Components (coloured FUELTANK
in parts) was throughout BODYWORK
all project stages from Pillion Seat,
Rear Sub-Frame adjustable Rider Seat,
Scheming & Styling to & Brackets Heating System
Trial Build & Production.

Scheming of
Battery Tray & Gearchange Assembly &
Rear Mudguard LHS Control Plate
Fuel tank
Painted Panels

REAR
PACKAGE

CENTRE
PACKAGING
Frame Infills
 PROJECt engineering
tiger explorer stages

TESTING SUPPORT
DEVELOPMENT &
STYLING SUPPORT

PRODUCTION SUPPORT
TRIAL BUILD &
Delivery of initial design restrictions and intended overall geometry of the bike and ergonomics,
progress provisional packaging with iterations of overlayed styling sketches and scan data from
styling house’s clay model.
SCHEMING & DETAILING

Scheming of large packages, 3D CAD modelling triumph

and surfacing, calculations, FEA work, clearance checks, motorcycles
tolerance stacks, scheme and component drawings.
 PROJECt
control unit for SIEMENS VDO
hybrid electric vehicles AUTOMOTIVE
HYDRODYNAMIC SIMULATIONS
Underside
plate
Responsibility for mechanical design from concept to Electronic
pre-series production. components Sealing
The challenge to maximize the heat transfer from overheated
electronic components was resolved with the presented
mechanical and thermoflow solution as an alternative to Flanged
sealing Intermediate
conventional cooling systems. Patent is registered for the plate
presented cooler layout and flanged sealing design.
Coolant velocity Pressure drop
Cooler
Hybrid Vehicle Layouts with ECU location housing

Combustion Engine Combustion Engine COOLER VALIDATION

Clutch Starter Generator
ATM Clutch
Gearbox ATM
Gearbox
Top View Underside View
Starter Generator
ECU ECU Flanged sealing &
outside leakage Hydrodynamic tests Function tests Thermo camera tests
system for low
risk of electronics
COOLANT PATHWAY

contamination

PROTOTYPE
TESTING
B-0 Sample
on the Road
01 Cooler’s inlet 02 Inlet to cells 03 Cell’s inlet and 04 Outlet from
and parallel from one tank outlet meandering cells and
water flow flow entire cooler
PROJECt engineering responsibility for
tiger 1050 & designed packages & components
tiger sport

TIGER 1050 TIGER SPORT

MY2007
Production support: required
modifications as a feedback
from testing and service usage
to components like: frame,
swingarm, bodywork and harness.
MY2013
Chassis improvements to
increase rider and pillion
comfort, riding experience
and other styling changes.

Engineering stages for designed Components: bellypan, seat,

mudguard tray, underseat
components and packages: electronic components.
4Specification feasibility
4Scheming 4Styling support
4Detailing 4Prototyping triumph
motorcycles
PROJECT
HORIZONTAL MACHINING CENTRE “CPH 1-5” SIEMENS Motor
P=22kW; nmax=6500rpm
& ZF Gear box , ratio 1:1; 1:4
CNC RETROFIT - main spindle performance increase
The project is a proposal for machine-tool manufacturer
“STIMIN INDUSTRIES” to improve performances and stay
competitive with their CPH1-5 product.
Main drive and spindle has been re-designed to achieve a Synchronous V belt
rotational speed increase from 3200 to 5000rpm adopting ratio 1:1,3 GoodYear
new solutions for bearing lubrication, tool retaining system, Logic control system for
reading and orientation of the main spindle. reading the speed and
position of the main spindle

Driver sprocket 8-64S-62

Hydraulic
PolyChain Gates Rotating union, seals at:
25° angular contact ball bearings Main drive sprocket 105 bar; 120oC; 15000 rpm

fluid
4 x 7220 ACD QBC, SKF G-48S-MPB GoodYear Deublin

Air
Radial seal 19x3 A50
Bearing lubricators Busak Shamban Belleville washers
P=2000daN

Laminar sealing Air blow taper

rings, FEY

Tool coolant Tool coolant

Through coolant
tool-holder
ISO50 Taper

V Seal
Busak Shamban Turcon AQ-Seal 5
Busak Shamban

Clamp for tool Valve for tool Cylindrical roller bearing, Axial bearing Wear ring guides & Slydring
retention coolant Bearings cooling system double row NN3018, SKF BSA205C, SKF seals Busak Shamban
stimin industries
PROJECt
new model BIKE GEOMETRY
concept stage
Chassis triumph COMPETITORS & ERGONOMICS & MASS DISTRIBUTION
motorcycles BENCHMARKING Considerations for Selection of wheelbase,
Understanding the riding style, comfort, suspension parameters
competitors. rider and pillion and engine position;
NEW MODEL Character and interaction with bike determining the bike’s
Uniqueness components. Centre of Gravity and
confidentiality restricted model not released weight distribution.
were key attributes
achieved for this project.
Project aimed to investigate and define fundamental
chassis parameters of the new model outlined by
Product Planning department in the initial specification
document.

At the end of the concept stage a few deliverables SWINGARM

were met, ready for next engineering stage and start Swingarm design
with pivot point position WHEEL & TYRE SIZES
of full design team: whole bike 3D layout, provisional Compilation of up-to date
considering wheel travel,
packaging & reasons, patent search for non-conventional chain slack and RSU stroke. manufacturer’s tyre database;
designs, initial whole bike styling sketches with external Comparison stiffness analysis selection based on styling, stability
and handling considerations.
styling house. was carried out using ProMechanica.

Engineering feasibility was confirmed in selecting wheel

& tyre sizes, suspension travel and linkage design, seat
height, ergonomics, engine position, silencer volume,
centre packaging and rear package configuration for
base model and derivative.
Key areas were identified and suggestions made for
further investigation supported by a preliminary mule for
data recording.
SUSPENSION
Position of rear unit to find best
stroke and linkage design for a
rising rate suspension. Together
with swingarm and frame layout
the rear suspension became a
feature of the bike that will stand
out from its competitors.
MAIN HARNESS &
CENTRE PACKAGING
Provisional layout of main harness routing and
packaging of electrical components.
A non-conventional solution was pursued to
achieve an outstanding rear package configuration.
FRAME LAYOUT
Frame layout and key
components design considering
engine & swingarm mounts and
rear & centre packaging. Comparison stiffness
analysis was carried out using ProMechanica.
 ®

CONTACT

Romania
Tel: 0040 (0)771 122 830
contact@transylvania-engineering.ro
www.transylvania-engineering.ro

Brochure edition: March 2015

© Transylvania Engineering Services SRL
No reproduction in whole or in part without the written approval