DC Gear Motor Assembly for Articulating TV Mount
One of our current customers, a leading manufacturer of automation technology for the home and workplace, had been building a custom DC gear motor drive module for a conference room articulating TV mount.
There were a few different challenges with this particular project that ISL was able to overcome. Managing the manufacturing of this module required sourcing multiple components, including the tooling of 3 unique pieces, two of aluminum die-casting and one injection molded plastic, from several factories. A kit of 14 unique parts had to be ordered, received, inspected, inventoried and scheduled for production, processed in multiple steps on an assembly line, then inspected, tested and inventoried once again for future integration into a master product.
At the time, ISL was the supplier of the custom DC gear motor for this drive module. When we discovered that the customer was adding these additional components and production steps to complete the module, we recommended that ISL take over the management and production of the entire drive module. This included sourcing, tooling, assembling, testing, inspecting, packaging and warehousing the completed module. This ensured that the customer could receive a complete installable module on their assembly line at the exact time their master product was scheduled for production. The realized cost efficiencies, both in time and overhead, were substantial.
Custom Spur Gear Motor Used in Automated Locking Systems
We were asked to provide a high performance, highly reliable version of a common model spur gear motor that would also comply with international security standards within an automated locking system.
Our customer came to us with an existing gear motor that only lasted 1,500 – 2,000 cycles in their application. Since these motors would be used in high security lock systems, they needed to have an ultra-high reliability gear motor with a 50,000 cycle life. In addition to the motor’s reliability, it also had to conform to newly-tightened international security standards. Another issue was, once the end product was in the field, it would be very costly to field-service and replace these gear motors.
In a joint effort with our factory, ISL made modifications to the motor to meet the customer’s goal of 50,000 cycles. Among some of the innovations, we changed gear material from brass to a high-reliable stainless steel alloy in order to achieve long life and improved dependability.
After further testing, the ISL custom version exceeded 90K cycles before testing was halted. We were also able to do this without any NRE charges.