Moisture Sensor Cover
Overview
Focus:
Risk AssessmentIndustry:
IndustrialDimensions (mm):
195 x 75 x 35Weight (g):
83020-Year
Design Support
Simulation
Specialised Part
Aluminium Prototype
Short Lead Time
This is a moisture sensor cover for John Deere Ag tractors that are equipped with moisture sensors. The cover protects the sensor from dirt and damage during the harvests. Texmo Blank manufactures these parts at our facility in Coimbatore, India. We have been working with John Deere as a partner for 20 years. The concept to delivery time on this component was 6-8 weeks.
Concept Development & Material Selection
The Texmo Blank team was fully involved in the development of this component with the customer. Based on our expert advice and understanding of our manufacturing and process inputs, the customer made changes to the product design and manufacturing tolerances. A key change was made in relation to the product design in line with our die-manufacturing capabilities.
Stainless steel CF8 was chosen for this casting due to its resistance to corrosion. This part is often exposed to water and high moisture conditions, making this material ideal for this application.
Risk Identification & Simulation
We used simulation software to check for any defects that could occur as a result of the solidification process. Defects such as shrinkage and non-fill can be predicted via simulation and corrected before beginning manufacture.
We use a technical feasibility sheet to evaluate any risks in the manufacturing process to ensure the design we are agreeing to is feasible. We also use failure mode and effect analysis to check for risks along each production process.
Prototyping
For initial trials a prototype tool machined from aluminium was made for a low-volume sample run. This was more cost effective as it was quick to produce. The customer could assess the castings made in that low-volume run and either approve them or make changes.
During the first sample run we faced some distortion and metal penetration issues. We were able to reduce these issues after making some changes to the assembly orientation of the casting.
Manufacturing Processes
This part was made using our ceramic shell investment casting process with a robotic system. For the machining, we used turning and grinding machines.
This was a complex part to cast due to the presence of small ribs and different wall thicknesses. We were able to ensure a quality part was produced thanks to our gating, assembly method and consistency of manufacturing process. We hold specialised certifications that guarantee process stability and we work hard to stay up-to-date with concepts such as lean management to further ensure quality.
The length of the part meant that we needed to add a straightening process after heat treatment. This was necessary for us to achieve the correct flatness.
Quality Control & Testing
In order to maintain critical dimensions we machined after heat treatment. We undertook our standard production part approval process, which is a requisite for every customer to ensure quality. We also checked the parts visually before shipping them to the customer.
In addition, a part-specific defect image reference sheet was put in place to cover all aspects of the production process. This is always in place to help our shop-floor staff understand how to categorise good and bad parts when checking for quality.
Get In Touch
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