Problem & Context
A complex machined aluminum valve manifold needed to be redesigned to simplify manufacturing and reduce assembly cost. The original design used multiple press-fit components, increasing BOM complexity, assembly time, and risk of inconsistent performance.
Scope of Work
- Reverse-engineer the existing multi-port manifold (no drawings or models existed).
- Identify press-fit components that could be integrated into the base manifold geometry.
- Redesigned internal and external features to maintain required flow paths, solenoid valve mounting points, and inlet connections.
Technical Approach
Integrated former press-fit components into the manifold body by modifying internal passages and port geometry to preserve flow characteristics.
Through experimentation ensured the correct pressure drops across the valve ports matched the original design specifications.
Took into consideration the cost of manufacturing and the machining setup requirements to optimize for production efficiency.
Results
Reduced assembly cost by eliminating press-fit components and associated labor, with no increase in machining cost.
Improved consistency of pressure drop across manifold when valves energized, leading to more predictable system performance.
Maintained original envelope and interface locations to allow drop-in replacement for the legacy design.
(Models and drawings are omitted due to proprietary constraints)