The Challenge
A power equipment manufacturer needed to upgrade its current manual process for testing its electric lawn mowers to an automated one. The previous manual process was slow and produced inconsistent results. The company wanted a new automated system that was more reliable, efficient, and adaptable. It also needed the testers to be able to adjust the end-of-line (EOL) test stand to work with a variety of different electric lawn mower models and test configurations.
The test stand also had to test non-traditional components for electric lawn mowers. These specific models had a built-in wireless phone charger and a USB port that needed to be verified. As the project moved forward, the company significantly revised its technical requirements. Supply chain issues added another obstacle to meeting the company’s tight completion schedule.
The Solution
ACS designed, built, and commissioned a new EOL test stand capable of testing three different electric lawn mower models in a range of configurations. This specialized test stand provided the testing flexibility and reliability the company needed.
One unique challenge was designing equipment to test the integrated wireless cell phone charger. ACS had to get creative because there was no existing test solution on the market. The ACS team designed a casing using 3D printing to house commercially bought components. The team then integrated these components into the programmable logic controller (PLC) systems.
ACS engineers designed the PLC to reliably test different configurations. The PLC also provided safety monitoring that halts testing until an identified safety issue is resolved. The electric lawn mower test stand was designed to be integrated into the full assembly line. An automated transfer cart would take assembled electric lawn mowers off the incoming assembly line, check which test stand was available, and deliver the mower to that stand for testing. Once the mower was verified, a second automated transfer cart would return the tested electric lawn mower to the outgoing assembly line for packaging.
The Outcome
Working with ACS, the manufacturer achieved better reliability, adaptability, and efficiency in its end-of-line automation test process. The new test stand allowed users to change parameters and monitor test status throughout the process. The company increased testing throughput and improved quality control of electric lawn mowers sent to packaging.
Supply chain issues threatened a significant project delay. One supplier notified ACS of a delay two weeks before the scheduled delivery, stating the ordered components wouldn’t be available for another year. Using its supplier network and negotiation expertise, ACS secured the pieces from a combination of alternate suppliers.
ACS delivered and commissioned the new test stand at the manufacturer’s facility on schedule. The team accomplished this despite the stand requiring a redesign due to the company’s revised test objectives and the supply chain challenges. ACS met the client’s aggressive schedule by being flexible and responsive to their changing requirements, resulting in a test stand that met all their objectives and specifications.
Key Features
- Designed an end-of-line automation electric lawn mower test stand that accommodates three different electric lawn mower models and a variety of configurations, providing the manufacturer with a versatile solution.
- Provided an innovative, customized solution for testing an integrated wireless cell phone charger using 3D technology.
- Demonstrated flexibility and skilled negotiation in resolving sudden supply chain challenges and responding to the company’s changing objectives while completing the project on its original aggressive schedule.
ACS Services
- Designed, built, and commissioned new EOL test stands able to test three different electric lawn mower models in a range of configurations.
- Integrated the electric lawn mower test stand into the full assembly line.
- Performed Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT).
