Case Studies
Real-world results driven by Qualicom’s precision and innovation.
Customer Requirement & Industry Challenge
Customer Requirement & Industry Challenge
A leading metro train manufacturer required high-precision sensor discs for their traction motor assemblies. These discs play a crucial role in providing real-time speed and position feedback, ensuring smooth acceleration, braking, and energy efficiency.
Key Customer Requirements:
- Tight dimensional tolerance (±5 microns) to ensure accurate alignment with the motor shaft.
Precisely machined sensor slots and mounting holes for accurate signal detection. - ENP (Electroless Nickel Plating) with uniform thickness for wear resistance and corrosion protection.
- Minimal warpage and flatness deviation within 10 microns to ensure stability during high-speed rotation.
The customer faced several challenges with their existing supplier, including:
- Inconsistent bore diameter tolerances, leading to misalignment.
- Variation in ENP coating thickness, causing signal interference.
- Flatness deviations, resulting in sensor reading errors and increased maintenance costs.
Given the high safety and reliability standards in metro applications, the customer needed a precision machining partner capable of delivering sensor discs with flawless quality and repeatability.
Challenges in Machining Sensor Discs for Traction Motors
1. Achieving ±5 Micron Bore & Slot Tolerance
- Sensor discs have tight-fitting bores and precision slots that require micron-level accuracy.
- Tool deflection during boring can lead to out-of-tolerance dimensions, affecting disc alignment.
- Achieving this level of precision on a 4-axis VMC without secondary operations posed a significant challenge.
2. ENP (Electroless Nickel Plating) Thickness Control
- The ENP layer must be uniform (10-12 microns) across the surface to ensure corrosion resistance and accurate sensor readings.
- Variations in plating thickness can result in signal distortion, material buildup in critical areas, and coating failure under stress.
3. Maintaining Flatness & Structural Integrity
- The sensor disc rotates at high speeds, requiring precise flatness to prevent imbalance and vibrations.
- Improper clamping or uneven machining stress can lead to warpage, causing sensor misalignment and inaccurate readings.
Qualicom’s Precision Machining Approach
1 High-Precision Boring & Slot Machining on 4-Axis VMC
- Used customized boring tools with adaptive feed rate control to maintain bore diameters within ±5 microns.
- Designed specialized carbide end mills for slot machining, ensuring sharp, burr-free sensor slots.
- Developed rigid fixturing techniques to eliminate deflection and ensure repeatable accuracy.
2.. ENP Coating with Thickness Consistency & Adhesion Control
- Partnered with an ISO-certified ENP facility to ensure precise plating thickness across all batches.
- Implemented post-plating dimensional checks using CMM scanning to verify uniformity.
- Conducted adhesion testing to confirm coating durability under operational stress.
3. Flatness & Warpage Prevention Techniques
- Applied stress-relief machining sequences to minimize material distortion after cutting.
- Used controlled clamping pressure to prevent unwanted deformation during VMC operations.
- Conducted final flatness inspection with CMM and laser measurement tools, ensuring minimal deviation.
Final Outcomes & Business Impact
By implementing precision machining strategies, plating control, and rigorous quality assurance, Qualicom successfully delivered high-performance sensor discs that met the customer’s expectations.
Key Achievements:
- Dimensional accuracy improved to ±5 microns, ensuring superior fit and function.
- ENP coating thickness controlled at 10-12 microns for consistent corrosion protection.
- Flatness deviation reduced, eliminating warpage issues.
- Rejection rate reduced significantly, improving overall quality and reliability.
- Customer secured a long-term supply agreement for metro traction components.
By delivering precision-machined sensor discs with flawless plating and structural integrity, Qualicom has reinforced its position as a trusted machining partner for the railway and metro industry.
Why Choose Qualicom for High-Precision Railway Components?
- Tight-tolerance CNC/VMC machining for critical railway applications
- Expertise in machining and coating processes like ENP plating.
- CMM-based quality inspection for consistent accuracy.
- Efficient process optimization for cost-effective production.
Looking for high-precision traction motor components? Contact Qualicom today to discuss your machining needs.
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