Electrolysis Machine
Electrolysis machines needed an update due to a outdated 1980s design with components no longer used. Device Solutions helped our client modernize their components, design, and processes.
A small firm acquired a legacy electrolysis product line from the original equipment manufacturer. This once-reliable electrolysis machine, originally designed in the 1980s, was beginning to show its age. With no documentation of circuit component changes or proper manufacturing and test procedures, customers were returning units. Factory yields were decreasing and, without updated design files or test procedures, there was no clear path forward. The machines suffered from EMI (electromagnetic interference) and RF issues, causing instability in the field. In addition, the factory test process was no longer adequate for today’s quality expectations. Our client wasn’t looking to reinvent their product, but they needed to restore its reliability.
The Solution
Device Solutions evaluated the full system, from legacy schematics to factory floor procedures. They began with a comprehensive hardware design review, leaning into their expertise in circuit design, RF systems, and EMI reduction to get to the heart of the problem.
The team made targeted recommendations to strengthen the product at three key levels:
Circuit Design Improvements: Optimized the assembly to reduce EMI and improve electrical performance, while working within the limitations of the original analog architecture.
Manufacturing Assembly Enhancements: Recommended the use of proper sockets and heatsinks for transistors, improved grounding strategies, and better component mounting to ensure long-term stability.
Factory Test Process Updates: Helped refine the test approach to catch issues earlier in the manufacturing process, improving yields and reducing costly returns.
Instead of a complete redesign, Device Solutions focused on practical, high-impact changes that honored the original design while bringing it up to modern standards.
The Results
With Device Solutions' support, the client regained control over their product. Factory yields improved, customer satisfaction rebounded, and the electrolysis machine returned to the field with renewed reliability.
The Summary
Services & Highlights
Circuit Analysis & Redesign
RF Engineering & EMI Mitigation
Test Protocol Development
Legacy System Documentation
Component Sourcing Consultation
Quality Assurance Implementation
Manufacturing Process Optimization and Support