Case Background
Customer's Products
Customer's Requirements
Difficult Point
Design Solution
Sample Production And Testing
Project scoring
Reference Value to you
Conclusion
Case Background
In August 2023, a Chinese manufacturer specializing in heat exchangers and heat sinks reached out for assistance in developing a custom storage solution for their water-cooling plates, a critical component of their products designed to improve cooling performance for IGBT (Insulated Gate Bipolar Transistor) devices. This case study explores the challenges faced by the client, the solutions proposed, the design and production process, and the outcomes of our collaboration.
The client, a leading manufacturer in the heat exchanger industry, has invested significantly in research and development to enhance the thermal management of electric vehicles. Their new product, the water-cooling plate, is designed to regulate temperature efficiently, addressing the substantial heat loss produced by IGBT components during operation. If not effectively managed, the excess heat poses severe risks, including irreversible damage to the IGBT and, consequently, jeopardizes the safety and stability of electric vehicles.
To succeed in their mission, the manufacturer required an efficient, reliable storage system for the water-cooling plates during various production stages.
Customer's Products-Water Cooling Plate
Customer's Requirements
After consulting with the client, we identified several critical requirements for the storage baskets:
| The baskets needed to be designed for easy stacking to optimize storage space. |
| The design should facilitate easy lifting and transportation. |
| The baskets must secure the water-cooling plates in place to prevent movement that could lead to scratches or damage. |
| Reducing the overall weight of the baskets was crucial for ease of handling. |
| A designated area for labels was necessary to track the progress of the products through various stages of production. |
Difficult Point
The baskets must secure the water-cooling plates in place to prevent movement that could lead to scratches or damage.
Understanding the client's technical requirements was fundamental to developing a suitable storage solution. Our design team quickly conceptualized a three-tier structure for the storage baskets that would meet the client's needs. The following design features were implemented:
Material Selection | The baskets were constructed from stainless steel wire, a material chosen for its durability and resistance to corrosion. We used cold-rolled round steel for welding, ensuring the structural integrity of the baskets while minimizing weight. |  |
Structural Engineering | The baskets featured a layered design to accommodate up to 16 water-cooling plates. Each compartment was individually designed to hold one plate securely, with two round steel rods positioned in the middle to stabilize the product. Additionally, small gaps between plates facilitated easy manual retrieval. | |
Ergonomics and Functionality | To enhance usability, we incorporated rounded corners instead of sharp edges, adhering to ergonomic design principles. The bottom was constructed with a dense mesh pattern to provide adequate weight support and ensure a flat surface for stability. | |
Labeling Solution | An additional stainless steel plate was affixed to the top edge of each basket to provide a designated area for labels, allowing operators to easily identify the stage of production for the contents. |
Sample Production And Testing
Once the design was finalized, we promptly moved to the prototype stage. Within five days, we successfully completed the sample production. To streamline the process further, given the proximity of the client's factory, we opted for direct delivery of the samples for testing.
Upon receiving the baskets, the client conducted rigorous quality assessments. The initial response was overwhelmingly positive; they were impressed with the quality, speed, and service provided. The functionality of the baskets during the testing process confirmed that they met the rigorous safety and usability standards required in their production line.
After two days of successful tests, the client promptly approved full-scale production of the custom wire storage baskets.
With the prototype validated and the client's approval secured, we shifted to mass production. Our production team maintained high-efficiency standards while ensuring quality control throughout the manufacturing process. The need for timely delivery was communicated, and we committed to meeting the client’s timeline.
| Project Scoring Communication: ★★★★★ Design Solution: ★★★★★ Quality Level: ★★★★★ Delivery Speed: ★★★★★ Customer Satisfaction: ★★★★★ |  |
Reference Value to You
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The collaboration between our team and the client resulted in:
Custom Solution: Development of a tailored storage basket that met all client specifications.
Enhanced Safety: The basket design secured the water-cooling plates, minimizing the risk of damage during storage and transport.
Operational Efficiency: The ergonomic design and stackability feature optimized storage space, making it easier for the client’s team to handle and organize components during the production process.
Positive Client Experience: The client's satisfaction with both the product and the service reinforced the value of effective communication, responsiveness, and innovation in problem-solving.
The success of our collaboration opens avenues for ongoing partnerships. As the client continues to innovate and develop new products in the heat management space, our company stands ready to support them with tailored storage solutions that enhance efficiency and safety in their operations.
In conclusion, this case study illustrates the importance of understanding client needs and addressing them through thoughtful design and efficient production processes. Our team’s commitment to quality and customer service not only fulfilled the immediate requirements of the project but also established a strong foundation for future collaborations.
If your parts or components are with special shape or size, don't worry about the storage problem, AUKE company with 17 years' experience is capable of designing a basket to meet all your requirements. Contact AUKE today or friend Linda on whatsapp: 0086-18261690816 for your own solution.
