A metal housing protected a multi-axis motion controller while supporting heat removal and connector alignment.
The customer’s challenge
Controller temperature caused shutdowns, shielding continuity was inadequate, and the interface panel did not align with the main board.
Material and fabrication route
2.0 mm aluminum housing; 1.5 mm steel base.
Process route: Laser cutting → bending → welding → thermal-interface application → fin machining → powder coating → assembly.
Manufacturing changes
Machined fins and direct thermal paths connected the board to the housing. Conductive seam gaskets and revised interface location improved shielding and alignment.
Engineering analysis
The controller housing served as a mounting interface and part of the thermal path. Direct board-to-housing contact and machined fins addressed heat removal, while conductive gaskets and panel location addressed different electrical and mechanical interfaces. The full-load temperature and operating result describe the populated controller. A new board layout requires a new review of heat-source locations and connector geometry.
Inspection and project results
Full-load temperature rise reached ≤40 K. The configured controller passed the reported EMC check and operated without the previously observed shutdowns.
| Project measurement or production detail | Recorded value |
|---|---|
| Temperature rise | ≤40 K |
| Interfaces | ≥16 |
| Controller envelope | 300 × 200 × 80 mm |
These figures describe the project configuration and production scope above. Dimensional, material and production details are identified separately from performance tests. For a new order, the inspection method and acceptance criteria should be agreed against the released drawings.
Planning a similar OEM component
A useful RFQ for this application should make the following interfaces and acceptance requirements clear:
- Board and heat-source layout.
- Thermal-contact surfaces.
- Connector and panel alignment.
- Conductive seam and cooling acceptance.
Include the current drawing revision, mating-component information, quantities and required delivery sequence. Identifying unresolved requirements at quotation stage helps distinguish fabrication work from the equipment-level checks that the project needs.
For related manufacturing support, review our Robot Controller Enclosures and sheet metal quality capabilities. Use the existing quotation form below to share the drawing package for review.
