One key difference that separates these plastic parts from previously used materials is that they are laser welded. Laser welding meets the space requirements by enabling chemically resistant parts to fit into tight cavities, get compressed down, and then be welded into place. Additionally, laser welding is one of the only ways to complete this process without producing any debris. Vibration welding or ultrasonically welding can produce debris in the form of plastic particles, which can cause issues in high cleanliness applications. Recent Engineering innovations have enhanced the laser welding process; by simplifying it to a single laser that travels along a weld path. This type of process has become less expensive as less equipment and custom fixtures are needed.
Finally, Parker Chomerics automates the insert molding of compression limiters which eliminates creep under bolt tightening compression, which otherwise can cause screws to potentially loosen over time.
To get the full benefit from all these engineering innovations, Parker Chomerics has built quality and consistency into the manufacturing process from the very beginning. All the molding machines have machine-based process monitoring on them, ensuring each process parameter is maintained correctly every step of the way. From the loading plate to the welding process, a series of sensors and cameras confirms that each step has been completed correctly and all parts are properly aligned before it will allow the workcell system to go on to the next step. Finally, the system leak-tests all the components to confirm that they are sealed properly before it lets operators remove the part and pack it. The net result is the finished parts are validated for being correctly molded and pressure tested. This type of error-proofing of highly automated assembly processes is how we can guarantee zero defects.
Results
Through engineering innovation and error-proof manufacturing, automotive manufacturers can rest assured they are using high-quality, high-performing electric motors. Parker Chomerics has an industry leading quality record with its automotive partners, and is annually granted awards from OEMs for meeting and exceeding their quality standards. This type of low-cost, space-saving plastic solution from Parker Chomerics meets the product cooling needs while eliminating the potential for any defects.