Challenge:
Alkhorayef faced significant challenges with the production and maintenance of components used to hold copper windings in ESP motors. Traditional manufacturing methods resulted in long lead times and high costs due to the need for specialized tooling. Additionally, the complexity of the parts required frequent design updates and improvements, further increasing production time and costs. The need for a more efficient, reliable, and cost-effective solution was critical to enhance operational efficiency and reduce lead times.
Solution:
C Block Framed Parts
Namthaja proposed the use of 3D printed PEEK C blocks. The solution involved:
- Design for Additive Manufacturing (DFAM): The original C block design was optimized for 3D printing, ensuring high precision and performance while eliminating unnecessary features that complicated traditional manufacturing.
- Material Selection: PEEK was chosen for its excellent mechanical properties, high-temperature resistance, and durability, making it ideal for the operational environment of ESP motors.
- 3D Printing Technology: The C blocks were produced using advanced 3D printing technology, which allowed for rapid production and high accuracy. This method also enabled the creation of complex geometries that traditional methods could not achieve.
- Increased Efficiency & Reliability: The new C blocks significantly increased operational reliability and reduced downtime, enhancing the overall performance of the ESP motors.
- Cost Efficiency: Overall costs were reduced by eliminating the need for specialized tooling and reducing lead times, which minimized downtime and production delays.