Electrolysis Machine
A decades-old electrolysis machine was generating field returns and needed an engineering redesign.
Our client had a product with a loyal customer base and decades of market presence, but it was failing in the field. Originally designed in the 1980s, this electrolysis machine started generating customer returns and falling factory yields. There was no clear engineering path to fix either problem. The original design files no longer existed. What remained were aging paper schematics and a product that had outrun the test rigor it was built on.
The root causes were identifiable: EMI and RF instability were driving field failures, and the factory test process was no longer catching marginal units before they shipped. But without current design documentation, any remediation carried real risk of making things worse. Our client needed a disciplined outside eye and a plan for restoring product reliability.
The Solution
Device Solutions conducted a full system review, beginning from the original paper schematics all the way to the factory floor test process. The team then delivered a prioritized remediation plan without touching the underlying analog architecture.
Three areas drove the recovery:
1.) EMI and RF Stabilization
Root-cause analysis identified interference patterns causing field instability. DS redesigned the assembly layout to reduce EMI and restore consistent electrical performance across units.
2.) Assembly Process Corrections
Transistor mounting, grounding strategy, and thermal management were all contributing to long-term reliability failures. DS specified socket and heatsink standards and updated the assembly process accordingly.
3.) Factory Test Overhaul
The existing test process was passing units that failed in the field. DS rebuilt the test protocol to catch marginal units at the line, before they reached customers. Instead of a complete redesign, Device Solutions focused on practical, high-impact changes that honored the original design while bringing the product up to modern standards. The engagement was scoped deliberately: first, fix what was broken; second, document what existed; third, leave our client with a product they could manufacture and support without outside help.
The Results
With Device Solutions’ engagement, our client now had a stable product, a documented design baseline, and a factory test process they could trust. Field returns dropped. Yield consistency improved. And, for the first time in years, the engineering team had a clear picture of what they were building and why it worked.
The electrolysis machine didn't need to be reinvented. It needed to be understood, and it needed to be fixed with discipline. That's the engagement Device Solutions was built for.
The Summary
Services & Highlights
Circuit Analysis & Redesign
RF Engineering & EMI Mitigation
Manufacturing Process Optimization
Test Protocol Development
Legacy System Documentation