About Us | Design Process
Our design process uses a proprietary process modelled on Advanced Product Quality Planning (APQP) principles using FEA (Finite Element Analysis).
Our core focus is to work as an extension to our customer’s design capability from the outset. This means developing geared motor concepts for volume applications that meet exacting technical and commercial specifications. We contribute at every design level, from initial design sketches and 3D-concept models, through to rapid prototypes for ‘proof of concept’. Our geared motor solutions utilize metals and/or composite technologies to obtain the right level of performance and cost.
We use a 5-stage gateway process that encompasses initial design specification, concept, prototype, pre-production and finally production. We work within a multi-disciplinary team blending NPI design methodologies with advanced quality planning, production engineering, and end-to-end project management.
In tandem with extensive life tests, we rigorously analyse prototypes using ‘design failure mode effects analysis’ (FMEA and DFMEA) to ensure that the final production version is trouble-free.
We utilise leading software tools such as SolidWorks for 3D modelling and Finite Element Analysis (FEA), DonTyne and MathCAD modelling software.
These software tools are used to virtually model the various components within the geared motor before we expend cost and time manufacturing. Such software tools can model the performance, both statically and dynamically, to an extremely high level of accuracy. We can therefore provide estimated performance data very early in the design process.
In addition to optimising performance, the 3D modelling software is able to provide full rendered images that are amazingly lifelike. New and customised products can thus be assessed for both form and fit very early in the design process.
As well as general mechanical software tools, we use SPEED software for electro-magnetic modelling of motors. Many applications require a particular torque-speed characteristic from a given space envelope and SPEED is a specialist software tool that allows us to optimise the motor design before producing.
Ultimately, all the software tools provided allow us to reduce the development time considerably and deliver an optimum solution quickly and efficiently.
'Proof of concept' can be manufactured in literally days and at low cost using various additive processes such as selective laser sintering (SLS).
Once the software models are complete, we produce rapid prototypes (RP) using various additive processes such as selective laser sintering (SLS), fused deposition modelling (FDM), stereo lithography, as well as rapid casting technologies. The benefit of these technologies is that a ‘proof of concept’ can be manufactured in literally days and at low cost. Depending on the type of technology used, the rapid prototypes can be used as space samples through to working samples to test form fit and function.
The benefit of rapid prototyping is that working samples can be provided at a fraction of the cost compared to using conventional methods.
We bench test product using high-performance dynamometers as well as simulate applications using our well-equipped 24x7 test facility.
We use high-performance dynamometers as well as simulating applications using LabView or a range of application specific test-equipment. Using National Instruments software, we can provide SPC analysis on all test data to model and test the ultimate life of the product. Apart from the usual performance criteria such as torque, speed, power, axial and radial loads etc., we can test for strength, fatigue, noise (acoustic and electrical), vibration and full EMC and environmental test facilities with our partner company, TRaC.
Our test facility also houses customer-specific equipment that we use to ensure our test data is as near as possible to our customer simulations, therefore reducing time to market.
Call us today so we can start designing the perfect solution to your geared motor needs.