Case study

Challenge

• Our customer approached us when they were tasked with sourcing a suitable gear motor for a new electric lock mechanism, designed to be used in ‘panic bars’ on emergency exit doors.
• The motor needed to be robust and have a long lifetime due to the life-saving situations the product was going to be used in.

Solution

• We reviewed the designs and suggested we begin by testing a spur gearmotor.
• Our customer rigorously tested this motor and it transpired that it wasn’t strong enough for the intended load so wouldn’t perform well in an emergency situation.
• Based on the feedback we received, a planetary gearmotor was then recommended as this is a stronger motor and is more effective with high speed so would have a quicker reaction time.
• We provided a selection of cost-down initiatives that supported the customer and reduced the overall cost of the lock system.

Results

• The new lock was launched onto the market and has had several years of consistent sales and good customer feedback.
• As the demand for the lock has grown we have supported our customer in scaling up production, as well as helping them out when they have had periods of sudden high demand including a special order for a new residential development project.
• The range of electric door locks was extended and Precision Microdrives now supplies gear motors for an expanded collection of electric locks.

STAGE 1

Designing for application

• Our customer was looking for a robust gearmotor that would be strong enough to work in an emergency but would not be large and bulky. The lock was going to be used in a variety of different settings including prestigious office developments, hospitals and airports so needed to look stylish as well as be functional.
• The lock mechanism needed to be able to withstand changes in temperatures as it would be mounted on external doors that would be exposed to a wide variety of weather conditions when the door was opened.
• They had a clear idea of the strength of gearmotor they were looking for, but lacked the knowledge on the type of motor they needed. We reviewed the specification and suggested a couple of different types of gearmotors for them to test.

STAGE 2

Manufacturing and testing

• We supported our customer as they tested a selection of different types of gearmotors. We found a planetary gearmotor that met all their requirements and would release the door latch within two seconds.
• Our customer performed temperature, environmental and mechanical tests, to ensure the motor would perform as expected in a variety of different conditions.
• We also tested the lock to ensure it would be compatible with most building access control systems as wanted to enable buyers to be able to integrate it into their building controlled access systems.
• Once the motor had been thoroughly tested and the prototype had passed all its checks, the device went into full production.

STAGE 3

Results and relationship

• The lock was certified as BS EN1125:2008, fire-rated and awarded the CE mark for safety and peace of mind.
• We have agreed on a flexible manufacturing agreement as this reduces their supply chain risk when their needs change.
• Now owned by an international door hardware manufacturer who have expanded the range of electronic locks and continued to engaged us to support them with this growth.