Background

An existing customer invited Optimas to explore a cost saving initiative relating to an electrical control box in a commercial air conditioning unit. Prior innovation failed to develop a fastening solution which would yield cost savings.

The original design of the control box enclosure contains a large steel stamping along with an outer casing that is installed on the face of the cabinet. This acts as a sealed unit to prevent leaks and moisture. 

The internal plate is designed and manufactured with a large range of pre-pierced holes to house every potential electrical component configuration. On average, the customer only used 30% of the holes built into the electrical control box.

Challenge

A cost–and labor–savings initiative that eliminated an under–used part of an electrical control box in a commercial air conditioning unit.

Action

Design a “dimple” style fastening system, including a range of sharp-crested, thread–forming screws, that engages on contact with walls and:

• Adheres to UL production requirements
• Eases the mounting process during manufacturing
• Allows for “change outs” in the field
• Ensures a watertight seal

Results

• “Dimple” design eliminated the electrical control box inner panel and passed UL, weather and transit testing.
• Re-designed screws lowered the torque required for installation compared to standard thread-forming fasteners.
• Eliminated debris created or left in the joint during thethreading/installation.
• Field repairs/additional components can be made with standard machine screws installed into existing threads.