Case study

Challenge

• Our customer’s machines were being upgraded to handle larger quantities of pill and tablets.
• In some climates the humidity would cause the tablets to temporarily block the internal pathways of the machine.

Solution

• A kit of long lasting vibration motors that could be affixed to the machine hoppers in several locations.
• We designed a long-life brushed motor with custom eccentric mass, to hit a target vibration frequency and amplitude, to induce resonance.

Results

• We used a spot-welding manufacturing technique for the chassis, and added a PCB backpack onto the motor to include an X2Y EMI filter.
• Provided an innovative solution and created an end-of-line testing station to ensure frequency and amplitude targets were met.

STAGE 1

Designing for application

• The first technical job on this project was to understand the frequency and magnitude of vibration required to hit mechanical resonance, and dislodge blockages within the machine.
• We had been given lifetime and environmental requirements, and after initial prototype testing our team designed a long-life brushed motor with eccentric mass that would hit the target vibration frequency and amplitude.

STAGE 2

Manufacturing and testing

• The customer confirmed the preferred fixing points on their machine, and we designed a chassis enclosure that would secure the motor whilst protecting it from humidity and dust.
• We used a spot-welding manufacturing technique for the chassis, and added a PCB backpack onto the motor to include a EMI filter.
• The flying leads were secured with epoxy to the PCB backpack, for strain relief. The whole wiring harness was secured further with a spot-welded strain relief fixture onto the chassis.

STAGE 3

Precision delivery

• The two motors, fixing components, wire sets and driver module, were all serialised, labelled and kitted together into a single carton package with protective foam and fitting instructions. 
• PMD’s testing infrastructure allowed us to assure our client that the product was verified and reliable, managing their risk throughout.
• Every production batch was delivered on time and to spec. 
• Positive relationship, leading to follow-up collaborations.