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What common mistakes do you need to avoid in electromechanical fabrication and testing?

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Electromechanical fabrication and testing involve designing, building, and evaluating devices that combine electrical and mechanical components, such as motors, sensors, actuators, and controllers. This field requires a high level of precision, accuracy, and creativity, as well as a solid understanding of the principles and practices of both electrical and mechanical engineering. However, even the most experienced and skilled electromechanical engineers can make some common mistakes that can compromise the quality, performance, and safety of their products. Here are some of the most frequent errors that you need to avoid in electromechanical fabrication and testing, and how to prevent or correct them.

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Ken Harpin

Senior Test Engineer at Hayward Industries, Inc.

1 Poor Documentation

One of the most important aspects of any engineering project is documentation. Documentation is the process of recording and organizing all the information related to the design, fabrication, testing, and maintenance of a device, such as specifications, drawings, schematics, codes, manuals, and reports. Documentation helps you to keep track of your progress, communicate with your team and clients, troubleshoot problems, and improve your future work. Poor documentation can lead to confusion, errors, delays, and failures in your electromechanical fabrication and testing process. To avoid this mistake, you should always document your work thoroughly, clearly, and consistently, using standard formats and tools, and update your documentation regularly and accurately.

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Ken Harpin

Senior Test Engineer at Hayward Industries, Inc.
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Neglected technical documentation can snowball into a tremendous technical debt. A few years ago, my company purchased one of our competitors who turned out to have some of the worst documentation I have ever seen. We ended up reverse-engineering the entire product line and redoing everything-- it was expensive, time-consuming and tremendously wasteful.

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2 Inadequate Testing

Another common mistake in electromechanical fabrication and testing is inadequate testing. Testing is the process of verifying and validating the functionality, performance, and reliability of a device, using various methods and tools, such as simulations, measurements, inspections, and experiments. Testing helps you to identify and fix any defects, errors, or issues in your device, as well as to optimize its efficiency and quality. Inadequate testing can result in faulty or suboptimal devices that can cause problems or hazards in their operation or application. To avoid this mistake, you should always test your device thoroughly, systematically, and rigorously, using appropriate test plans, procedures, and equipment, and follow the relevant standards and regulations.

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Ken Harpin

Senior Test Engineer at Hayward Industries, Inc.
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A responsible manufacturer will do sufficient subsystem and functional testing to ensure that their customers are receiving a safe, functional, reliable product. Abbreviating or skipping tests may seem like a way to save costs in the short term, but the end result is that the customer becomes the final inspector when they open the box. Multi-million-dollar government contracts have been lost because the manufacturer shipped an untested product that failed catastrophically in the customer's hands.

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3 Wrong Materials

A third common mistake in electromechanical fabrication and testing is using the wrong materials. Materials are the substances that make up the physical structure and properties of a device, such as metals, plastics, ceramics, or composites. Materials affect the strength, durability, weight, cost, and performance of a device, as well as its compatibility with other components and environments. Using the wrong materials can compromise the quality and functionality of your device, as well as cause damage or failure in its fabrication or testing process. To avoid this mistake, you should always choose the right materials for your device, based on their characteristics, specifications, and requirements, and use them correctly and safely, following the best practices and guidelines.

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Ken Harpin

Senior Test Engineer at Hayward Industries, Inc.
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In electromechanical design, it's important to pick materials that complement one another. One of the motor driver products I once worked with had several high-power components secured to a heavy aluminum heatsink using stainless steel screws. The problem was that the stainless-steel screws would gall and jam in the aluminum tapped holes, preventing the drive components from torquing down correctly, which caused them to overheat and fail prematurely. Once we discovered this, changing out the stainless-steel screws for zinc parts dramatically improved the product's long-term reliability.

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4 Improper Wiring

A fourth common mistake in electromechanical fabrication and testing is improper wiring. Wiring is the process of connecting the electrical components of a device, such as wires, cables, connectors, switches, and circuits. Wiring affects the power supply, signal transmission, and control of a device, as well as its safety and efficiency. Improper wiring can cause short circuits, overloads, malfunctions, or fires in your device, as well as interfere with its mechanical components and functions. To avoid this mistake, you should always wire your device properly, neatly, and securely, using the right wires, connectors, and tools, and follow the electrical codes and standards.

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5 Faulty Calibration

A fifth common mistake in electromechanical fabrication and testing is faulty calibration. Calibration is the process of adjusting and aligning the mechanical and electrical components of a device, such as sensors, actuators, and controllers, to ensure their accuracy, consistency, and compatibility. Calibration affects the performance, stability, and feedback of a device, as well as its interaction with other devices and systems. Faulty calibration can lead to errors, deviations, or conflicts in your device, as well as affect its operation or application. To avoid this mistake, you should always calibrate your device carefully, accurately, and regularly, using the right methods, tools, and references, and check and correct any discrepancies or drifts.

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6 Lack of Creativity

A sixth common mistake in electromechanical fabrication and testing is lack of creativity. Creativity is the ability to generate and implement new and original ideas, solutions, and improvements for your device, based on your knowledge, skills, and imagination. Creativity helps you to overcome challenges, enhance your design, optimize your fabrication and testing process, and create innovative and competitive products. Lack of creativity can limit your potential, reduce your quality, and hinder your progress in electromechanical engineering. To avoid this mistake, you should always foster your creativity, by exploring different possibilities, seeking inspiration, learning new skills, collaborating with others, and experimenting with new approaches.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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What common mistakes do you need to avoid in electromechanical fabrication and testing?

1

2

3

4

5

6

7

1 Poor Documentation

2 Inadequate Testing

3 Wrong Materials

4 Improper Wiring

5 Faulty Calibration

6 Lack of Creativity

7 Here’s what else to consider

Mechanics

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What common mistakes do you need to avoid in electromechanical fabrication and testing?

1

2

3

4

5

6

7

1 Poor Documentation

2 Inadequate Testing

3 Wrong Materials

4 Improper Wiring

5 Faulty Calibration

6 Lack of Creativity

7 Here’s what else to consider

Mechanics

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