CASE STUDY: Sourcing Linear for High-Accuracy Drop Testing in Harsh Outdoor Conditions
Recently, ACORN’s linear division received a call from a specialist engineering customer that designs and tests equipment for hazardous environments, including demanding programmes in nuclear and subsea settings. This time, the work wasn’t happening in a neat lab with polished floors and predictable conditions. They were heading outdoors, into a quarry, where winter air and grit complicate testing processes.
The task was to build a drop testing rig for destructive testing of canisters intended to carry nuclear and radioactive waste. The brief sounded simple, but in practice was brutal: guide a 120kg offset mass down an 18-metre fall, reach roughly 19 m/s, and hi the target point with high accuracy. That kind of speed magnifies every small misalignment and compromise in installation. Add corrosion and contamination resistance to the requires, and the system had to be tough as well as precise.
The stakes were made even higher by the test programme itself. There were only eight sample pieces available, leaving no spare runs. Once a sample was used, it was used. The solution therefore had to perform first time, with very little room for error.
The customer had already gathered competitive quotations from other suppliers, but they were searching for a better fit, with a jump in performance or a meaningful reduction in cost. Linear & Automation Product Manager, Garry Haines reviewed the options with the end use in mind; thinking about what would install cleanly, run consistently, and stay dependable through cold, wet weeks on an exposed site.
After comparing several approaches, ACORN recommended the Rollon Speedy Rail systems at the best fit. It offered improved performance, a more straightforward and faster installation, and a lower cost then the competing proposals. To remove uncertainty before the first drop ever happened, ACORN arranged a joint visit with the customer alongside Rollon’s engineers. They used the on-site walkthrough to confirm the final specification and ensure the selected configuration matched the realities of the rig, the environment, and the accuracy demanded. With the specification agreed, ACCORN submitted a quotation for the complete project kit.
The outcome was exactly what the programme needed: successful testing, consistent performance, and reliability in winter conditions over several weeks. The Rollon Speedy Rail was singled out by the customer as ‘one of the best parts of the whole thing’, a telling compliment in a project where most components only get noticed when they fail.
When the test campaign finished, the rig was dismantled and the guides could be reused on other projects, reducing both environmental impact and future spend.
In the end, ACORN delivered more than a component choice. The project balanced precision with practicality, and speed with control, in a setting that offered no second chances and no comfortable margins. Our dedicated Linear & Automation Division are on hand for any projects, even in difficult situations.