Case Studies

  • Industrial Product Development: Case #1

    Challenge:

    A customer came to us for a complete redesign of their flagship industrial product – a high power emergency backup system for building safety systems.

    GOALS:

    Sine-wave output, power increase, efficiency improvement, increased functionality and fault detection, size reduction, reliability improvement, obsolescent components mitigation

    SOLUTION:

    PI developed a comprehensive solution comprising novel designs for electrical/power, embedded, mechanical, and battery technology.

    OUTCOME:

    The project was completed on time and on-budget, and the customer was able to maintain their lead in the industry and push into new markets. Power output was doubled over their existing unit, manufacturing cost reduced by 20% and mechanical volume reduced by 25%.

  • Sustaining Engineering: Case #2

    Challenge:

    An oilfield service company was concerned with reliability and cost of an electromechanical assembly. They retained the PI team to redesign the packaging concept.

    GOALS:

    Cost reduction, reliability improvement.

    SOLUTION:

    A thorough dimensional and tolerance analysis was performed, and problems with tolerance stack-up which led to production issues were identified.

    A new single-piece chassis design was created and the pressure rating of a communications interface port was increased. New assembly procedures were also developed.

    OUTCOME:

    The project was completed on time and on-budget, and the customer was able to realize the improvements they sought. The complexity of manufacturing process was reduced, and the product reliability was increased.

  • Sustaining Engineering: Case #3

    Challenge:

    A global provider of energy technology needed to address a potential high-voltage safety issue with an existing product. The PI team was engaged to handle the project.

    GOALS:

    Issue resolution, backward compatibility, low cost.

    SOLUTION:

    A small electronic module was developed and packaged to allow for a seamless retrofit of existing products. Solution was tested extensively and integrated into the overall system.

    OUTCOME:

    Existing units were upgraded, and the new design was incorporated into current and future production units. The project was finished on time and on budget.

  • Manufacturing Automation: Case #4

    Challenge:

    A manufacturer of high-accuracy geophysical instrumentation needed an accurate and precise 3-D magnetic field mapping system.

    GOALS:

    Meet stringent accuracy and precision requirements, map field in three dimensions.

    SOLUTION:

    A system was developed which combined a high-accuracy gauss meter with a high-precision motion system.

    OUTCOME:

    The magnet-mapping station met all requirements and allowed the customer to fully characterize their magnet systems in-house.

  • Manufacturing Automation: Case #5

    Challenge:

    A leading pharmaceutical company had a need for high-throughput configuration and production test for roll-out of a new drug delivery system. They engaged the PetroMar Industrial team for the project based on our experience with automated test systems and precision measurement.

    GOALS:

    High accuracy, high-throughput, low cost, fast time-to-market.

    SOLUTION:

    A set of automated test fixtures, procedures, software and a data management system based on SQL database was designed to meet all customer and regulatory requirements.

    OUTCOME:

    The targeted production line is on track for meeting its commercial goals.

  • Manufacturing & Documentation: Case #6

    Challenge:

    An industry leading provider of downhole technology engaged PI’s parent PetroMar Technologies to develop a new well logging tool. The customer now needed to build the production units.

    GOALS:

    Manufacture the pilot production fleet for the new complex downhole electromechanical system, designed to operate at 165C temperature and 20,000 psi pressure.

    SOLUTION:

    The PI team launched a thorough manufacturing planning and costing effort which allowed us to quote aggressively on cost and schedule for the customer.

    OUTCOME:

    The pilot production was awarded to PetroMar Industrial and is under way and on schedule.

  • Manufacturing & Documentation: Case #7

    Challenge:

    A leading provider of high-reliability power converters asked PI’s parent, PetroMar Technologies, to develop a very high temperature (210ºC) converter for downhole and other high temp markets. After initial prototype result met requirements, a manufacturing run of qualification units was needed.

    GOALS:

    Provide top-level electromechanical assembly of the 210C electronics modules.

    SOLUTION:

    PI procured and kitted parts, wrote and refined assembly procedures, and assembled and tested the HTCC units.

    OUTCOME:

    Qualification units were built on time and budget. All passed manufacturing testing and as a result product qualification was launched.