About the Customer
Cablecraft Motion Controls was approached by a prominent supplier in the exhaust gas management system industry. The customer specializes in producing systems for hybrid vehicles, which require a customized solution to control a diverter valve in the exhaust gas stream. The application called for a high-performance actuator linkage to meet the demanding environmental conditions that hybrid vehicle components endure.
Customer Problem/Need
The customer faced several significant challenges in the development of this actuator linkage:
- Harsh Operating Environment: The linkage needed to operate in extreme conditions, including high temperatures, severe vibration, and exposure to dirt and corrosive elements.
- Cost Constraints: Given the high production volume for hybrid vehicles, the solution had to be cost-effective.
- Durability: The customer’s initial design, which featured a steel-on-steel rod end, was prone to failure in the corrosive environment, leading to a need for a more durable material.
- Complex Testing Requirements: The development process for passenger vehicle components required lengthy and rigorous validation and testing, adding complexity to the project.
To meet these challenges, the customer needed a robust solution that could withstand extreme conditions, reduce costs, and ensure reliability throughout the lifecycle of the component.
Solution
Cablecraft Motion Controls developed an innovative and cost-effective actuator linkage solution by leveraging their expertise in motion control engineering and their collaborative approach with the customer.
- New Race Material Development: We identified a key area for improvement in the customer’s original design. The existing steel-on-steel rod end would not hold up in the harsh environment, so we developed a polymer race material rated at 575°F, which was suitable for the cooler side of the linkage. This material was a compromise between the customer’s initial high-cost options, providing an affordable solution while still meeting the temperature requirements.
- Supplier Collaboration for Molding: During the development of the polymer race, our team recognized the need for a new supplier capable of molding the high-performance material. We worked closely with this new supplier to meet the customer’s Production Part Approval Process (PPAP) timing, ensuring that the solution was tested and validated within the tight timeline.
- Prototyping and Testing: Our sales and product engineering teams collaborated extensively with the customer’s OEM team, enabling rapid prototype development. The prototypes underwent rigorous validation testing in both Michigan and Europe to ensure they met the demanding performance criteria.
- Value-Added Solutions: In addition to providing a more cost-effective race material, Cablecraft implemented further cost-containment measures. By providing a pre-installed lever as part of the overall assembly, we saved the customer valuable time and reduced costs in their assembly process.
- Scaling Up for Increased Demand: The initial volume estimate for the actuator linkage was 35,000 units in the first year, but demand far exceeded expectations. To keep pace with this growth, our team invested in new equipment and processes, allowing them to ramp up production without any disruption. This expansion was made possible by our flexible lean manufacturing environment, which is well-suited to handling a wide range of OEM applications.
Results
The collaboration between Cablecraft, the customer, and the new supplier led to a highly successful project. Cablecraft’s innovative approach not only met the technical and environmental requirements of the actuator linkage but also provided significant cost savings and production efficiencies for the customer.
Our extensive engineering expertise, rapid prototyping, and ability to deliver value-added solutions have solidified a lasting relationship with the customer. Thanks to this successful project, we continue to serve as a trusted supplier, adapting to increasing demand while maintaining high-quality standards.
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