Marine Autopilot

Re-engineering a substandard product

Engineering problem

The task – analyse and improve an NPI that had critical safety failure modes related to gear, clutch and electric motor.

Investigation process

Starting with a comprehensive DFMEA study, a Six Sigma analysis of all manufactured parts and a tolerance analysis of the critical gear system and belt mechanisms.

Root cause of failure was established through multiple extended life tests in the lab.

Redesign and production

The housings were redesigned to add stiffness and support to the gear system, which was slipping under torque loads.

After tooling trials, first off components were approved in Asian supplier factories.

New assembly

Many parts needed to be updated in the final assembly:

Redesigned wormgear drive

New clutch spring profile

Uprated motor

Carbon tipped belts

Housing modified from PC/ABS to 20% glass filled PC with additional stiffeners throughout

New gaskets and seal profiles

Life testing

Once the assembly was completed, the product underwent rigorous life-testing both in the chamber and onboard <10m powerboats in the Solent and the US.

Waterproof testing to IPx6 marine rating was also carried out.

The engineering modifications were proven to solve the initial problems that the product exhibited.

Relaunch

The new version SPX-5R was approved for mass-production, relaunched and is in use around the world in many small powerboats.