The importance of mechanics, design and tooling in the PEP

Every product is based on an idea. This usually arises from everyday situations, is initially not defined and must be substantiated to ensure the product's success. The earlier the mechanical development & test equipment construction department is involved in the product development process (PDP), the better the project can be supported. Department head André Bisig takes you on a journey through the product development process and explains the importance of design and mechanics.

An idea is developed into a product. In the first step, this idea must be specified in a catalogue of requirements, i.e. use cases must be described and concrete indications of the area of application must be provided. This catalogue of requirements serves as the basis for the specifications, in which the customer defines the most important points and communicates desired deadlines.

Once the idea has been fleshed out and described, the project begins with the feasibility study.

Phase 1: Feasibility / Concept

In this phase of product development, the feasibility of the idea is examined. The core task of mechanical development in this phase is to technically examine the customer's task and to search for and compare possible solutions for the requirements. It is about the housing, the interfaces, the tool production and later assembly in production, because these in turn have an influence on the required operating resources.

Thanks to the complete package of electronics, mechanics, test equipment construction and tool manufacturing that STEINEL Solutions offers in the field of product development, an optimal alignment with internal manufacturing capabilities takes place at an early stage.

On completion of the feasibility phase, there is an initial production-optimised design proposal for the new product and a product concept that defines the required parts, mainly central system components, as well as interfaces. Now, equipment and tools can be budgeted and the development costs estimated in a fairly precise range.

Thanks to the many years of experience in implementing solutions in a wide range of industries that our development specialists bring with them, STEINEL is able to define the framework conditions in a set of specifications after the feasibility study. Once all the important information has been collected internally, a channelled exchange of knowledge and insights with the customer takes place.

Assessment | André Bisig

"Ideas for new products usually come directly from our customers. They know the industry and how their products are used in practice. Once the idea has been formalised in a catalogue of requirements or a specification sheet, consulting begins as an important part of my work. We know what questions to ask, what points to clarify and which details are crucial for successful implementation. So, ideas for optimising new and existing products often come from STEINEL."

"The feasibility study is of central importance for the entire project. On the one hand, it is about creating a common understanding of the product, but also of the market (field of application) and the business model (transport/logistics). On the other hand, a cost- and production-optimised realisation of the product should be ensured – and this in the shortest possible time-to-market. Thanks to our agile set-up and many years of experience, we can offer significant added value here, becausesmooth, interdisciplinaryinteractionbetween all the technical specialists involved, from the fields of mechanics, electronics, technical office, project management and purchasing, is extremely important. In addition to physical and technical requirements, financial requirements, tasks to be performed, hourly estimates, necessary approvals, the right choice of materials and alternative parts are also determined."

Phase 2: Development

The product concept created for the components reaches prototype status in the development phase. With the help of CAD, the individual components are designed, taking into account the process technologies and the relevant standards, and the complete assembly is created.

The core task of mechanical development is to adapt the construction optimally to the subsequent production technology, since this varies depending on whether it is a plastic housing manufactured by injection moulding or sheet metal parts. The overarching goal is to optimise production, costs and interfaces. The development of a manufacturing concept that defines how the various parts are to be joined, e.g. by clicking or screwing, is therefore also part of this project phase.

Assembly of engine brake at the workplace. Development

The mechanical development work (yin) is closely interwoven with the electronics development (yang); the symbiosis ultimately leads to the product. The cooperation between the specialists involved in the project is essential for a successful project outcome and an optimally implemented end product.

For example, it is periodically checked whether the designed housings also match the planned electronic parts and which connection points are important. The mechanics department also supports the electronics development team in the construction of provisional test setups for carrying out measurements.

Communication between departments and project management at STEINEL is very direct, which is a huge advantage. Especially when it comes to clarifying details in the team.

In the next step, the manufactured parts are assembled to create a prototype that most closely resembles the end product. As the name suggests, the focus of these functional models is on functionality. However, the structure can also be used to visualise the design, for the customer to hold the first 3D sample in their hands or for cables to be inserted for testing purposes, for example.

Thanks to our in-house 3D printer with SLS (selective laser sintering) technology, a wide range of functional models can be printed in a very short time. This enables rapid insights into individual functions and ensures agility and flexibility.

If more stable materials are required, a wide range of parts can be machined in STEINEL's in-house mechanical engineering department. For special cases, STEINEL has a network of external partners that can be contacted if necessary.

Once the product has been developed to this stage and is largely complete, a mechanical and electronic design and process FMEA (failure modes and effects analysis) is carried out with the aim of identifying and evaluating potential sources of error at an early stage in the product development process and implementing suitable improvements.

As soon as the customer has accepted the prototype, the industrialisation phase begins.

Assessment | André Bisig

Employee sitting in front of two monitors with CAD drawings during the development of a mechanical component

"One of our added values is that, in addition to electronics, we also offer mechanical development, as well as the construction of operating and testing equipment. At STEINEL, we work in interdisciplinary teams of specialists, all in one office. As mechanical developers, my colleagues in the electronics development department are important points of contact. A successful project team also includes our project manager and a technical contact at the customer's end. Since we work with agile project management methods at STEINEL, we can react very quickly to changing requirements or conditions."

André Bisig developing a mechanical component.

Insight into 3D printer and cleaning station for 3D printed parts with 3D print dust, manual reworking of samples with blue gloves,

"The change from design (theory) to mechanics (practice) provides variety in our department and in-depth knowledge in both areas. We can best test and check the functionality of prototypes under real conditions thanks to mechanical devices. We are always happy to go the extra mile here. For example, we used a pneumatic device to perform an endurance test on the buttons of a control unit, or we moved a grid hinge back and forth 10,000 times, to give two examples."

André Bisig works on a sample from the 3D printer.

Phase 3: Industrialisation & test series

The industrialisation phase is of central importance for series production and a further central task of design and mechanics. The fact that the services of mechanics and equipment construction are offered from a single specialist area and, at the same time, proximity to production is guaranteed, is a speciality and a central advantage at STEINEL Solutions.

While the operating equipment is being built in Einsiedeln, STEINEL has other specialists in the group who take care of tool procurement, including, for example, injection moulding tools. The focus is on lean management, because the production process should be designed to be as efficient as possible.

The operating equipment, including assembly devices, bolting devices, punching devices or soldering frames, are evaluated, designed and later realised on the basis of the 3D data and the prototypes or first test series parts. Depending on the planned quantities and customer requirements, the operating equipment is automated, semi-automated or designed for manual use.

3D CAD drawing of the latch plate press and the realisation

One example of a piece of equipment designed and built in Einsiedeln to customer specifications is a press for plug-in tabs. Six plug-in tabs are pressed into two PCBs simultaneously and twelve plug-in tabs are tested in the same step.

Another example is a UV exposure unit with automatic drawer opening for UV adhesive curing, in which the inserted parts are evenly exposed so that the UV adhesive is also cured evenly.

Small bending devices for PIR sensors, swivelling soldering devices, bending pressing devices or rubber punching devices for SENSOTEC HB PIR Wire, for example, are also manufactured in-house.

Once the tools, operating equipment and test equipment are available, the test series follows, which is also carried out in Einsiedeln. The parts are compared with the drawing and tested for their mechanical function. In addition, the tool capability is checked for the last time by means of an initial sample test report.

Depending on the product, various tests are carried out on the end product either internally or externally in this phase, such as adhesion tests or leak tests. The STEINEL Group has a range of measuring equipment available, including an IP test system, a measuring machine and a 3D scanner. Tests under real-life conditions are part of the daily routine, for example standardised drop tests without packaging from different heights or impact tests on a linear luminaire with a ball pendulum (500 g or 5 kg) that crashes into the luminaire with momentum. STEINEL also has a rain chamber and a climate cabinet for testing temperature and humidity resistance by running or setting various cycles - hot/cold, dry/damp and time-dependent - through parts under demanding conditions.

If the tests are successful, the parts are approved. Process reliability is ensured by means of operating and test equipment capability certificates and work instructions.

Assessment | André Bisig

Two people in ESD protective clothing are laughing as they look at a printed circuit board in a test device.

"The importance of industrialisation has increased significantly, and the testing concept is of central importance for market success and approval. Products are becoming more intelligent, more complex and at the same time smaller. For example, larger cable harnesses have to be installed in smaller spaces. Proximity between development and production is crucial for success in the pilot series. We can solve many issues hand in hand. This keeps communication channels short and saves us valuable time!"

André Bisig and Reto Schmid, Head of Assembly & Testing, examine a testing device.

"In any case, the assembly of the equipment takes place at our premises. We assemble the ordered parts, test them and optimise them where necessary. It is therefore an added value that the designers have access to their own mechanical engineering department with specialists and an internal mechanical workshop. We have a wide range of machinery. This includes, among other things, gluing robots, ultrasonic welding machines, painting robots, casting machines and much more."

One of several gluing robots at STEINEL.

Employee in ESD protective clothing works on the inner workings of a test instrument

"Before each commissioning of a testing device, the fixture must be inspected, individually adjusted and, if necessary, adapted. The fact that a functioning testing concept is created before series production is crucial. Safety is the top priority here, along with high product quality and, above all, the safety of the end user. We have many years of experience in creating successful testing concepts, which is an enormous advantage for customers."

André Bisig works on the inner workings of a testing device.

3D drawing and sketch of a universal test adapter for printed circuit boards

"Optimisation suggestions come from the customer or are proposed by STEINEL. For example, we expanded the housing of a ceiling sensor with an additional "slot" to make it easier to install and remove the sensor. For another product, we developed a "clamping point" to hold the slider more firmly in the mould. The constant review and optimisation of various devices and equipment in production also falls within the scope of the design and mechanics, as does the review of their functionality and handling."

IPA by an apprentice; universal test adapter for printed circuit boards.

Phase 4: Start of production / pilot production

All documents, including parts lists, operating resources, production times, work instructions or test specifications, are updated again shortly before the series release with the so-called zero series.

In this phase, various mechanical tests are carried out in internal and external test laboratories as part of the approval process in accordance with standards. These include IP tests, IK, vibration, shock, transport test, and others. One of the areas of expertise of STEINEL Solutions is to support the approval process.

Internal approval by quality management is based on internal test reports, test reports from the approval bodies and all necessary declarations of conformity. After internal approval, the samples are inspected and approved by the customer.

Phase 5: Series production support / CIP

The parts are now in series production. To ensure that the product remains successful, every employee is called upon from this point on, because only those who understand the product can recognise potential for improvement. If mechanical changes are required during series production, these can be implemented in an efficient time frame because all the necessary mechanical resources are available. The mechanical development department is also involved in the series production support and provides assistance in optimising processes with mechanical devices.

An idea has become a product. Of central importance in the product development process: mechanical engineering.

Portrait of the employee who wrote the article

"For me, it's very important to identify with STEINEL Solutions and the products that are being developed. Working on different projects in a range of sectors is a daily challenge for me, but it's also a real pleasure. I enjoy seeing how the products are created with the associated tools, equipment and test equipment, and helping to design them. After all, it takes a certain amount of courage and creativity!"

André Bisig, Mechanics developer at STEINEL Solutions AG