Case study

Challenge

• The customer approached us whilst in production, and already using a gear motor. However, they were experiencing inconsistent quality and shorter than expected lifetime issues, with the motors from their existing Chinese supplier.
• They were looking for a more reliable and robust motor, with a longer-life time due to the difficulty in replacing them, in some of the locations where their water collection devices are used.
• They needed a new motor supplier who could work with them to resolve the issues they were experiencing.
• Their team understood the technology they were using but had little practical experience with gear motors.

Solution

• The customer sent us their current design drawings, and samples of the gear motor they were using.
• We took the time to review everything they sent and questioned them on the application details. This allowed us to fully understand the engineering and technology they were involved with.
• We found that the motors were mounted in an area of high humidity and moisture in the device making the use of the existing brushed motors unsuitable.
• Since the motor location could not be changed, our engineers designed a solution that used an encapsulated brushless gear motor with a custom housing. This protected the motor from exposure to moisture and corrosion.

Results

• Our application engineers designed a solution that would drop into the device, so there were no additional adaptations or manufacturing costs.
• Our solution resolved all the issues the customer was experiencing and reduced the need for their engineers to complete on-site maintenance checks, thereby reducing the company’s carbon footprint.
• The customer decided to choose us as their primary supplier. They appreciated, that although our solution had a larger upfront cost, it worked out to be more cost-effective over the lifetime of the device.

STAGE 1

Designing for application

• Our first task was to review the motor samples and application specifications the customer had sent to fully understand the technology being used, along with the problems they were experiencing.
• By carefully reviewing the information shared with us, our application engineers discovered that the current motors were not fit for purpose.
• They also discovered they had no IP (Ingress Protection) protection, despite them being positioned in an area with high exposure to moisture and humidity.

STAGE 2

Testing and finalising

• Our application engineers developed a solution that used a longer-life encapsulated brushless gear motor with a custom housing that would provide IP protection while avoiding the risk of the motor overheating.
• Our solution was heavily tested including environmental, IP (Ingress Protection) against dust and moisture and longevity testing. 
• We also ensured that we developed a drop-in solution (with an integrated brushless driver) so the customer did not need to redesign their device or make any changes to their production line.

STAGE 3

Results and relationship

• Due to our engineering teams investing time to fully understand the technology used in this device, we were able to diagnose the underlying issue the customer was experiencing.
• The customer appreciated that despite a higher upfront cost, our solution was cheaper overall.
• Furthermore, it improved both the reliability of their device and helped to reduce their carbon footprint by reducing the number of on-site visits their field engineers needed to carry out.