Objective

Evaluate between 3 coating types on lead screws and guide rods to quantify if their friction reduction can eliminate actuator jamming seen in the field due to grease contamination.

Process

• Developed linear actuator force measurement fixture:
  • SolidWorks design
  • Laser cut sheet metal
  • Press brake forming
  • Tack and filler welding to strengthen joints
• Tracked 9 metrics to identify whether there could be other causes to the actuator jamming such as motor current, run time to failure, motor temp, shaft temp using oscilloscopes, timers and infrared thermometers

Result

Coatings were effective only as a short term solution, as they peeled off after 2 days. My findings drove the team's decision to switch the actuator position in the gas grill to prevent grease from contacting the actuator.