Mechanical Design · Simulation-Driven · 2023

Reverse Engineering of
Train Braking Systems

Brake triangles reproduced locally for CC2200 and CC3300-AC locomotives at CAMRAIL — reverse engineered from worn originals using traditional measurement, precise 2D/3D documentation, and a transition from SMAW to MIG-MAG welding for improved structural integrity.

CC3300-AC brake triangle after completing the Douala–Yaoundé route via Esseka — validation of the reproduced component under real operating conditions
Year 2023
Role Designer · Reverse Engineering Specialist
Employer CAMRAIL
Team Gille · Mbella Jacques · Ricardo
Category Mechanical Design · Simulation-Driven

Project Case Study

The Problem

The CC2200 and CC3300-AC are veteran locomotives in CAMRAIL's fleet. Their age means original spare parts are no longer available on the market — creating a maintenance crisis each time a critical component fails. Brake triangles were among the most urgent: worn or broken units could not be replaced through normal procurement channels.

Our team of four engineers was tasked with reproducing two fully functional brake triangles — one for each locomotive type — using locally available materials, tooling, and expertise. The components had to match the original geometry precisely enough to integrate directly into the existing systems, with durability and performance comparable to the imported originals.

An additional constraint was the need to transition from the existing Shielded Metal Arc Welding (SMAW) process to MIG-MAG welding, using newly acquired Lincoln Electric Power MIG 360MP and Fronius TransSteel 2700 units, to meet higher structural standards for railway service.

The Approach

My specific responsibility was the production of all detailed 2D drawings and 3D models, ensuring every dimension and tolerance remained within manufacturable limits while guaranteeing compatibility with the original locomotive interfaces.

For the CC3300, the team used UPN profiles bent and cut into the required shapes, with end caps added to achieve the correct mass and diameter — a solution I proposed. For the CC3300-AC, rectangular iron bars were machined and shaped into circular forms matching the original triangles.

Throughout both builds, I applied traditional reverse engineering methods — manual measurement with calipers and measuring tapes, geometric analysis, precise dimensioning, and tolerance verification — iterating closely with Mbella Jacques and Ricardo to ensure that what was designed on paper was actually manufacturable with the available machines. Each stage moved from raw material, through machining and welding, to functional testing against the reference components.

The Outcome

Both brake triangles were manufactured, assembled, and validated. The CC3300-AC unit completed the full Douala–Yaoundé route via Esseka — a real-world validation under operational conditions that confirmed the reproduced component performed to specification.

The most valuable lesson from this project was one about the limits of design-office thinking. I had initially applied tolerances that assumed workshop capabilities I was used to from previous contexts — which proved incompatible with the tools actually available. This cost the team significant rework time. Working more closely with Mbella Jacques and consulting him before finalising dimensions resolved the cycle quickly and produced better results.

As the project reminded me: "If you want to go fast, go alone; if you want to go far, go together." In engineering, designing in isolation is rarely optimal. The designer and the manufacturer are not opponents in a tolerance negotiation — they are collaborators in the same problem.

Technical Documentation

Interested in this type of work?

I'm available for reverse engineering, railway and industrial component documentation, and precision 2D/3D modelling for local manufacture in Africa.

Let's Work Together All Projects