As a result we have extensive knowledge of many manufacturing processes, understanding their strengths, weaknesses and limitations
we can suggest the most cost effective process to suit your company needs.
Elson Designs was selected to improve the design and productivity for an existing product with annual sales in excess of 2000 units.
Previous design consultancy had advised the Investment Casting process for design criteria.
Elson Designs discussed their requirements and suggested an Extrusion was the most cost effective solution.
As costing example below shows, extrusion alone produced an Annual Saving of
£486,000.
Access to secure backplane was very difficult. PCB's assy were guided onto backplane. PCB's assy were screwed to casting. RH side connector alignment was very difficult. LH side connector build-up was very difficult. Interconnecting cables were prone to damage. Cover secured.
Saving 92%
Assembly was aided by sub-assemblies Backplane assy was secured to extrusion. PCB's assy were guided onto backplane. Connector plate assembly was secured to extrusion which also secured PCB's.
Assembly time was reduced by over an hour Product reliability improved.
Thermal modelling allows us the luxury of understanding thermal issues before committing to expensive tooling! We can view hot spots see thermal mapping, air flow and transient time (time taken to reach saturation).
With this knowledge we can manipulate the design to give optimum heat transfer by heat-sinks, stirrer fans or component positioning, even down to PCB component level.
Thermal simulation reduces development time plus the cost and embarrassment of a product thermal redesign.
Maximum heat output was 950 watts. Main heat carriers were 8mm thick copper plates clamped to an aluminium heat sink. External fans were required.
Radio designed for the rail industry to operate in ambient up to 70 degrees C. Average power output 21.5 watts peeking to 35 watts for 5 minutes. Internal stirrer fans required, fans were internally switch on when internal temperature reached 55 degrees C to increase fan life.
