This project began with a customer’s request to solve quality issues of their existing design. Disk drives were falling out of their guides, the backplane had poor and inconsistent alignment, etc. We performed an analysis and recommended against a band-aid approach. We convinced them that we could resolve their legacy issues and reduce costs while maintaining reverse compatibility with the drives, power supply and backplane. This was a long standing product and serviceability needed to be maintain with so many units in the field.
We started from scratch. By using out knowledge in sheet metal fabrication we were able to take an approach that designed out many tolerance stackups. Fitting of all components were greatly improved, manufacturing repeatability increased and fabrication and assembly costs went down. The drive alignment and backplane issues were easily resolved. Our customer was happy with the results as was their customer with the reduction in costs.
Our intervention gave this rack mount chassis product many more years of life.