CALTHERM CORPORATION

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CALTHERM CORPORATION

• David Langenderfer
• Fall 2004 Coop Session
• Department of Mechanical Engineering, IUPUI
• Intern/Coop Presentations March 24, 2005

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Introduction

• Co-op at Caltherm Corporation in Fall 2003,
  Summer 2004 and Fall 2004
• Engineering Lab Associate Fall 2003
• Manufacturing Engineer Summer 2004
• Lab Engineer Fall 2004
• BSME Senior

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Description of Caltherm

• Manufacturing Facility in Columbus, IN opened in
  1979
• Supply diesel engine thermostats
• 60,000 sq. ft. over 150 employees
• Acquired Vernay Labs in 1987
• Acquired Eaton thermostats in 2003

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Description of Duties

• Design various close and stamp tooling
• Design multiple leak test fixtures
• Update documentation
• Kan Ban implementation
• Spring vs. Dead weight rack comparison
• Upgraded life cycle testing procedure
• Designed and implemented new high pressure test
  stand

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Tooling Designs

• Designed prototype close tooling for balanced
  thermostat for CAT
• Designed new tooling for the V-Stat line
• Designed prototype close tooling for Pressure
  Relief Valve for Racor.
• Adjustable die for squeeze push element
• Plate for life cycle testing
• Adjustable plate for sensor

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Various Tooling
Original V-Stat Tooling
Adjustable Die
V-Stat Tooling
V-Stat Tooling
Plate for Life Cycle Tester
Adjustable Sensor
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Leak Test Fixture

• Modified existing design to accommodate new seal
• Designed using Solid Edge, created and assembled
  features to determine the appropriate fit
• Sent to tool room to be made
• Created work instruction on how to use the leak
  test fixture

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Leak Test Fixtures
Modification of Original Fixture
New / Original
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Update Documentation

• Create APQP documentation such as PFMEA, control
  plans, flow charts and work instructions
• Created flow charts for multiple low flow cells
• Checked and modified documentation on CAT side
  bump

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Kan Ban Implementation

• Determine the 25 most common wax mixes
• Create the Kan Ban board and tags
• Install the Kan Ban board
• Explain how to use the Kan Ban to the involved
  employees

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Spring vs. Dead Weight

• Create a test procedure for testing the
  difference between a spring and dead weight rack
• Test the two racks with multiple elements and
  various temperatures
• Report my findings

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Life Cycle Test Procedure

• Increase accuracy
• Increase repeatability
• Easier replacement
• Ability to run 24 hours
• Refill system

Test Fixture
Preliminary Fill System
Fill Tubes
Final Fill System
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High Pressure Stand

• Pressure drop
• Measure flow
• Look professional
• Safety
• Quick part changes

Electrical Enclosure
Reservoir Motor/Pump
Measurement Area
High Pressure Stand
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Other Tasks

• Create safety features
• Create fluid recovery system
• Modify wiper seal line
• Design parts rack
• Design coolant mister
• Modify Harley-Davidson tooling

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Safety Shield on Wax Inject
Light Curtain on Wiper Seal Close Press
Wiper Seal Press
Mister for Squeeze Push
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Float Control for Fluid Recovery System
Fluid Recovery System Holding Tank
Harley-Davidson Tooling
Parts Rack for Wiper Seal
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• Any questions?