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This trip unit was
originally fabricated from three steel stampings which included
pre-punched locating and mounting holes. After the assembly, seven
critical location holes had to be drilled.
The stamping and welding process
caused significant warping problems. This affected the overall
repeatability, which led to fixturing problems and created machining
difficulties.
The trip unit mounts onto a
premolded plastic panel. The flatness on the bottom surface is very
critical for proper function. This flatness requirement, as well as
design restrictions caused by the premolded plastic panel
components, provided a major challenge in the part and mold design
for PIAD engineers.
In close cooperation with the
customer's engineering staff, we were able to design a multi-cavity
mold which produces a part which has a repeatability of .004"
on the mounting hole location and guarantees a flatness of
.005" T.I.R on the bottom surface.
The PIAD casting has reduced the
secondary operations to only four drilled holes and one tapped hole.
The tapped hole is precast. The need for zinc-chromate corrosion
protection has been eliminated because of the good corrosion
resistance of PIAD's Alloy M010.
The casting design for this Trip
Bracket won the "International Casting Competition Award"
sponsored by Modern Metals in 1992.
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