Fastener cuts assembly time at motor manufacturer

An innovative fastening technique, developed for a motor control gear production line, has led to reduced assembly times, reduced stock costs and has eased maintenance for the manufacturer. Serco Ryan provided up front design advice for motor manufacturer Brook Crompton on its control panel terminal assembly line and was asked to reduce the number of components and the number of different types of fastener being used while still meeting safety regulations. The traditional method for connecting three terminals to the steel control panel required a total of eighteen fasteners, including six different types, increasing assembly time and making repair or service difficult. "The design brief had strict parameters in which to work," explained Jason Williams, applications engineer at Serco Ryan. "We were asked to fit an M5 bolt through the mild steel base plate to provide the connection stud without letting bolt heads protrude out of the back and eliminate the chance of the whole unit rotating in the hole during assembly or maintenance. "The casing was too thin for a countersunk head bolt so we recommended that a clinch stud be used and supplied to the base plate manufacturers, who would be better equipped to press them into the casing prior to delivery. Brook Crompton could then reduce the number of production stages, component costs, time and the need for investment in new equipment." The number of fasteners and operations required to fit each terminal was halved and fewer components improved maintenance procedures. DP Pointers * The new fastening solution has cut assembly time, reduced stocks and improved maintenance procedures for fitting the terminal to the control panel * The number of fasteners and operations required for assembly was halved * Clinch studs were supplied to the base plate manufacturers, who pressed them into the casing prior to delivery to Brook Crompton