Case study

Challenge

• Our customer had designed a handheld blood gas testing device that could deliver lab-quality results at a patient’s bedside in minutes.
• We worked with the customer’s specification to develop a miniature gear motor and encoder solution.
• One of the key requirements they had was 1600 encoder counts per revolution to ensure precise sampling.
• The motor and encoder had to be re-validated due to the project being paused for 18 months during the Covid pandemic. After this, the product was re-scoped with cost downs.

Solution

• They tested and clinically trialled a gearmotor with an optical encoder.
• After an 18 month pause, the customer re-opened the project and with our support, tested and validated a new miniature gearmotor solution with a more cost-effective magnetic encoder.
• We supported the customer’s engineering team to validate the change from an optical encoder to a magnetic encoder. It maintained the accuracy they needed while enabling them to meet the tight cost reductions they had been set.

Results

• The samples passed all their tests and the clinical trials so were signed off and everything was ready to move into full production.
• Covid-19 had paused the project, during which the customer focused on other more critical life-saving projects.
• Due to the customer having a new timeline and cost constraints, a revised solution was designed to accommodate these changes and enabled them to meet their strict market launch date and target costs.

STAGE 1

Designing for application

• Our customer had developed an innovative method to test blood gas and reduce the waiting time for lab results to come through.
• After analysing the device requirements, our design engineers provided a solution using a gearmotor with a magnetic encoder.
• The motor and encoder had to perform to a strict set of criteria, including performance, environmental and endurance.
• Small changes were made to the encoder’s PCB header to enhance its reliability.

STAGE 2

Testing and finalising

• We supplied samples with five-pin connectors for their clinical trials. These were tested and validated.
• The gearmotor with a new magnetic encoder was thoroughly tested including minimal voltage and brownout tests as they wanted to ensure it would work at a reduced (low battery) voltage.
• The new solution passed all their tests and the clinical trials, so they were approved and went into full production.

STAGE 3

Results and relationship

• Our London and Hong Kong based engineering teams found a solution that was more cost and time-efficient, so the customer could meet their new launch deadline.
• Due to the technical knowledge and expertise of our team, the customer decided to choose us as their primary supplier for the motors in the device.
• The customer is now working to complete FDA approvals, so they can expand their market into the US.
• Their latest order covers their needs for the next 12 months.