CASE STUDIES
PARK PAWL
TRANSMISSION PARK PAWL TRANSFORMATION TO FINEBLANK
Background
A major automotive Tier 1 manufacturer had several parking pawl types and needed to consolidate designs.
The automotive customer was using powdered metal and considering a forged or cast then machined parking pawl.
Solution
MPI and customer engineering collaborated to design a low cost fine blanked solution.
Higher performance low cost fine blanked design with welded spacer. Lower grinding and machining costs.
Problem
The parking pawl required a complex multi-dimensional long obtuse design with variable thickness.
The customer required a high-performance, low-cost solution.
Impact
High performance, low cost fine blanked parking pawl design to support ICE engine for years to come.
Hydraulic Fluid Power
Hydraulic Fluid Power Customer Flatness Requirement
Background
High efficiency fluid power pump manufacturers require valve/pressure plates with extremely tight flatness tolerances to avoid leaks.
Solution
MPI and the customer designed cost effective valve/pressure plates with world class flatness.
Used grinding and lapping processes to achieve flatness not possible with machining.
Developed repeatability and inline inspection techniques
Challenge
The customer needs valve plates and pressure plates in high volumes with flatness below 0.005mm.
Precision valve and pressure plates must be cost effective.
Customers prefer a North American solution.
Impact
High quality, cost competitive, precision valve and pressure plates the customers can expand into other complex applications.
Facilitates shift of customer valve plate sourcing from higher cost Europe to North America.
Tone Wheel
Heavy Truck Tone Wheel
Background
A heavy truck transmission manufacturer’s tone wheels required expensive hobbing and machining. Additionally, they could not maintain flatness because of distortion during heat treat.
Solution
MPI and customer engineering developed a fine blanked 2-piece tone wheel with a separate heat treated center thrust washer.
Eliminated excessive high cost hobbing and machining.
Lower heat treating cost with better consistency
Challenge
Design and manufacture a high-quality, low-cost transmission tone wheel with extreme flatness
Impact
High performance heavy truck tone wheels. Tight tolerance including superior repeatable flatness.
Lower cost tone wheels for heavy truck transmissions.
EV Battery
EV Battery Collector Plate
Background
Our customer, an electric vehicle OEM is expanding battery production in North America.
The customer needs a reliable, certified supplier for super high volume, small aluminum battery collector plates.
Current Asian suppliers will not move to North America and there are no obvious local manufacturers
Solution
A high-speed aluminum stamping line with inline washing and gaging systems to ensure clean, defect free parts.
Running at 400+ strokes per minute with automated packaging to minimize cost.
Challenge
Develop a high speed, thin gage aluminum stamping capability at MPI.
Deliver battery disks with high cleanliness and quality specifications while offering competitive pricing.
Sophisticated packaging and handling requirement.
Impact
Project currently in progress. Start of production in 3Q 2024.