The Customer
The customer stands at the forefront of energy management solutions, renowned for its commitment to innovation and reliability in utility management. As a global leader, the company has set high standards in the development of gas meters, devices crucial for accurate and efficient energy distribution. These meters are designed to serve in a diverse array of environmental conditions around the world, making their durability and reliability paramount to ensuring uninterrupted service over extended periods.
The Challenge
The primary challenge faced by the customer was the development of gas meters capable of withstanding extreme environmental conditions for up to 20 years. This endeavor necessitated a solution that could endure a rigorous salt spray test of 1100 hours at 85% humidity and a temperature of 85°C, simulating the harsh conditions these meters would encounter. The goal was not only to ensure the meters' operational integrity but also to guarantee their longevity across various climates globally.
The PICA Solution
In response to the customer's stringent requirements, PICA Manufacturing Solutions recommended the adoption of high-reliability Flat Flex Cable (FFC) material, alongside hard tooling techniques to precisely shape and bend the FFC in alignment with the customer's drawings. This innovative approach was complemented by PICA's suggestion of special packaging to maintain the integrity of four uniquely shaped part numbers, addressing the mechanical and electrical bend requirements effectively. Furthermore, PICA undertook a comprehensive Production Part Approval Process (PPAP) at Level 4 for these part numbers, ensuring exhaustive verification through control plans, process flow diagrams, and measurement system analysis.
The Result
The collaboration between the customer and PICA culminated in the successful implementation of Flat Flex Cable technology within the gas meters, thereby meeting the stringent electrical and mechanical requirements set forth. This partnership not only exemplified the seamless integration of legacy technology with modern engineering solutions but also affirmed the meters' capability to withstand the test of time in diverse environmental conditions. The rigorous PPAP Level 4 process further solidified the reliability of the production assemblies, marking a significant milestone in utility management solutions. Through innovation, rigorous testing, and quality assurance, the customer and PICA have set a new benchmark in the development of durable, reliable gas meters for the global market.