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Advanced Engineering |
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Designing a solenoid actuator for a critical performance/price target is no fun . . . |
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unless you're working with Ledex® and Dormeyer® Actuation Products. Perhaps it's the confidence of fifty plus years of expertise. Maybe it's the 3-D CAD, computer modeling and the latest automated assembly equipment. Or, maybe it's the skill, determination and loyalty of our employees who have helped grow our business into the industry's largest.
Perhaps, it's our customers, like you, who challenge us with requirements such as faster cycling speeds, precise repeatability, longer life and lower unit cost. Whatever the reason for our success, we know it's working. And top vendor recognition awards from leading businesses continue to prove it. |
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Ledex® and Dormeyer® products product design engineering resources, available through our Vandalia facility, offer assistance in resolving complex actuation problems. Our staff of applications and design engineers have unmatched experience in solving complex motion control problems. |
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Design Engineering |
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Although we have an extensive line of standard products, many of the designs our customers purchase are unique to their requirements. As a result, our applications engineering staff has extensive experience in solving unique customer requirements. Call them at 937/454-2345.
Ledex® and Dormeyer® Products engineers are well versed in actuator applications from military missile systems to disk drives. Consequently, our customers are assured of engineering depth and experience to guarantee the successful solution of a particular problem.
Our engineering staff, CAD specialists and fully equipped model shop have hundreds of man/years of experience in actuator design and development. |
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Engineering and Manufacturing Evaluation |
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The design for manufacturing phase begins with an engineering evaluation and prototyping process which typically takes 2-4 weeks.
The design team will value-engineer the proposed product with quality assurance and test the product to eliminate problems which could lead to non-conformance to your performance criteria.
Simultaneously, Ledex product manufacturing reviews their needs for internal and perhaps external piece part production to comply with the overall quality, cost and performance requirements of the product. |
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Pre-Production |
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The pre-production phase includes the testing of the proposed product's design for mass production, including the testing equipment, processes and controls to be used in final production. At this point, the engineering design is finalized.
A design review is completed with Manufacturing, Sales, Engineering, and Quality Assurance. Quality Assurance works with -Engineering to determine critical-to-function requirements and the critical points for Failure Mode and Effect Analisys (FMEA).
The desired inspection controls for each operation are checked and the inspection employees are trained for the characteristics to be inspected. Similarly, pre-production finalizes routings by working with the appropriate supervisors, operators and assembly personnel so that all employees are well trained. New processes are supported with process specifications. |
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CAD and FEA |
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Ledex engineers use a variety of computer design aids such as CAD and FEA (Finite Element Analysis) in order to create your prototypes quickly, accurately, economically.
FEA is a mathematical modeling technique resulting in design optimization at the onset of the design process. The software assists the design engineer in predicting the performance of an actuator by calculating values of flux density and force which may not be otherwise easily obtained.
As a result your prototypes are available more quickly because production trial and error is eliminated. Ledex products were among the first to utilize FEA computer-based coil design and performance models. |
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Kicking the "Electronic Tires." |
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A quick overview of how we develop a concept that's right for you |
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It wasn't too long ago that an application's worst case system stroke and force values, sometimes including arbitrary safety factors, were used to determine a solenoid's minimum performance requirement. Oversized, high inertia, complex and overly expensive systems were all too often the end result.
Smart engineers today understand that designing for production results in the most cost-effective solution. We take your inputs such as dimensions, mass and power, plus worst case stroke and force, in order to simulate a design that represents the most cost-efficient production build.
We employ the latest technological tools such as solid modeling, CAD and FEA (Finite Element Analysis) to quickly and efficiently build electronic and physical prototypes to meet your application requirements. For example, FEA is a mathematical modeling technique resulting in design optimization at the onset of the design process. The software assists the design engineer in predicting the performance of an actuator by calculating values of flux density and force which may not be otherwise easily obtained. As a result your prototypes are available more quickly because production trial and error is eliminated. Our products were among the first to utilize computer-based coil design and performance models. |
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3-D modeling (right and below) provides a clear picture of your product before major prototyping costs are incurred. |
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Individual drawings are pulled directly from the 3-D model. |
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Automated test fixtures gather performance data to pick up trends and guarantee high Cpk values. |
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Our software literally "builds" your assembly, cycling parts through their tolerance range. This gives the range of strokes the actuator must bridge. This information is then fed into the rigid-body-motion-simulator to understand how the physical tolerances affect the work required by the actuator.
The next step is designing an actuator using magnetic FEA and creating a model that can be imported into the circuit simulator. This gives the exact output of the system based on power input. This file can be turned into a solid model which can be exported to rapid prototyping. Continuing on,
cycling this output through the power range produces a force profile that can be linked back to the assembly-builder to compute a Cpk based on random variations in all part tolerances. Comparing Cpk to the calculated value, gives the opportunity to reduce costs, by widening tolerances and sometimes reducing solenoid size and weight. |
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File Format Help
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ZIP: Some files need to be unzipped. Unzip utilities available for download for Windows / Macintosh.
For technical difficulties with this page contact us here.
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