Case StudiesUtilized in a wide range of industries and applications around the world, Methode products have enabled some of the most critical systems to achieve industry-leading product performance. Through the success of our customers' products, Methode has become one of the most trusted providers of electromechanical solutions. Read some of our most recent success stories below.
Cross-Category Launch of User Interface Consoles for New Kitchen ProductsOne of the world’s largest white goods OEMs approached TouchSensor with the challenge of concurrently designing and launching twelve distinct, custom user interfaces, across four products… High Resolution Touch Screen for White Goods IndustryOne of the world's largest white-goods OEMs approached TouchSensor™ to design a user interface with consumer electronics-like performance for their premium brand’s new wall oven Solid-State Control Panel for Kia MotorsKia Motors approached Methode to create a new, in-car infotainment system to debut at the 2010 Consumer Electronics Show (CES). The goal was to transform the automobile’s… Next-Generation Biometric Access Control and Time and Attendance TerminalsA potential customer's existing range of products did not significantly stand out from the competition or adequately project the quality and functionality they offered Beverage Dispensing User Interface for Food Service IndustryThe customer’s technical team was intrigued by TouchSensor’s software-free TS100 field-effect touch technology. Capable of being mounted on standard printed circuit board material… Implementation of Innovative User Interface SolutionsOne of the world’s leading manufacturers of industrial cranes saw their competition gradually adding new features to their products to improve safety and usability… Ford Electronic Finish PanelsThe MyFord™ driver-connect technology project began after Ford thoroughly reviewed the current interior design and limitations, considering new and emerging technologies available…
High-Ratio Heat Sink Replaces Bonded-Fin SolutionA major UPS manufacturer faced a dilemma while developing a battery-backup system for wind-turbine power generators. The backup system helped maintain a constant overall power output by... Cost-Saving New Thermal Management Enclosure for WeldingA welding-equipment manufacturer expected to introduce the next-generation welder in a legacy enclosure, but the next-generation system required a heat sink whereas the previous system had required… Liquid-Cooled Chill Plate RedesignCustomers frequently ask us to simply fabricate something that they have already designed. Just as frequently, we are able to suggest an improved design approach… Quick Thermal Fix Saves Beta RunA leading traction-drive manufacturer was suffering system failures during beta testing. The failures were caused by an inadequately sized heat sink, which was causing power electronics to overheat… The Development of Extreme Copper TechnologyMethode's partner, UPE, developed the Extreme Copper PCB technology as a result of a customer’s need to handle very high-current values on a board containing small surface-mount devices… Heavy Copper PCBs in Automotive ApplicationsElectric Vehicle (EV) inverters represent one of the most demanding potential applications for Heavy Copper PCBs. EV batteries use high-power inverters to generate three-phase power for the AC… The Development of PowerLink TechnologyUPE developed PowerLink technology, which allows fine-pitch devices using standard copper traces to be mounted on the same surface with power devices… Advanced Mainframe Computer Power DistributionA team of designers from a major computer company needed to distribute power to numerous points within a large computer system. They desired a cost-effective solution that offered… Improved Telecommunications Power SystemsA telecommunications power distribution manufacturer required an improved fuse panel that would increase their system rating from 15A to 20A; giving them a competitive advantage… Reducing Inductance in Power Distribution SystemsIn October 2008, Methode’s laminated bus bars were featured in Bodo's Power Systems. The article, Laminated Bus Bar for Aerospace ApplicationAn aerospace company tasked Methode with creating a reliable-but-compact power-distribution system that would efficiently distribute power for a helicopter application. Our team developed… Telecommunication Data Router AssemblyA major telecommunications company approached Methode for design assistance on a new router system. The mechanical layout required an innovative manufacturing method to produce a power… Laminated and Powder Coated Bus Bars for Medical EquipmentLaminated bus bars are utilized for their space-saving, high frequency, high current capabilities and ability to conform to the specific application architecture. The power is coupled to electrolytic… Pluggable High-Power Distribution System Minimizes Server DowntimeMethode was approached by a high-end server customer. The servers process and store data for financial institutions and credit-card companies. Because any server downtime is very costly for this customer, Methode engineers were tasked… Laminated Bus Bars Meet Stringent Demands of Locomotive Traction DrivesWith demands such as temperature extremes, shock and vibration and surge testing with tens of thousands of Amperes, electric-powered locomotives have a heavy electrical load requirement. The customer also needed assurance… Bus Bar Solution for Misalignment in Scalable Server SystemThe customer desired a scalable design that would allow them to plug in modules to increase the capacity of their high-end server. The system operates at a very low DC voltage and thus a bus bar with minimal voltage drop was critical… Laminated Bus Bar Saves Product LaunchA customer was developing a new power-distribution unit with multiple shelves, and their goal was to have blind-mate capabilities for each drawer. They had attempted to develop the input power distribution internally… Router Power Cable from Power Supply to BackplaneThe customer required a very tight bending cable assembly to connect a 50A, 48 VDC source to a backplane located around a sharp corner. Methode engineers started with PowerFlexTM cable… Multi-Wire FusionLug Solves Reliability ProblemsThe customer distributed 48 VDC to three separate loads. The existing cable, consisting of a machined bracket with a large solder cup, failed frequently due to the cold solder joints… Power Cable for (n+1) Redundant Power SystemOur customer used two 48 VDC supplies configured in parallel to provide (n+1) redundant power to a telecom system. Each power supply was capable of delivering the full 150A load current… Custom FusionLug for Battery JumperMethode fabricated FusionLugs™ on the ends of a flat copper braid. A sense lead was included in the termination of one lug that served as voltage tap. Two diagonal countersink holes… FusionLug on Flat Braid for Low-Inductance AssemblyThe customer’s large system required a long internal power cable. The switching power supplies generated a lot of electrical noise, and long power cables can radiate that noise if… Long Power Cable for Hydrogen Fuel CellsWhen a customer asked us to design a power transmission system for field installations, in lieu of a rigid bus bar our engineers turned to Methode’s Parallel Power Cable for its flexibility… XP3 Custom Power ConnectorMethode was fortunate to have recently acquired the Tribotek™ connector technology, which features massively parallel internal contacts to lower contact resistance without a commensurate increase… Power & Signal Rover InterconnectThis application is for a mobile roaming unit (robot) powered by batteries that retrieves product in a warehouse. When the robot senses that its batteries need recharging, it automatically… Dual-Pole Battery Bus Bar ConnectorThis application involved an array of battery drawer units that blind-mate plugs into the system’s central bus bar, providing power to the bus bar. Methode was asked to develop a power connector… High-Voltage Medical ConnectorFor this application, Methode engineers determined PowerBud™ would satisfy the total current requirement without introducing excessive mating or unmating force, and designed a housing to hold… Interconnect Cost Reduction and Reliability ImprovementOur customer’s existing PCB-to-PCB interconnect design relied on jumper wires and crimped lug terminals, which proved very labor intensive and unreliable. Standard off-the-shelf connectors… Overheated Large Drive ConnectorOur customer’s existing connector generated excessive heat, often exceeding a 30 degree maximum temperature rise. The connector was difficult to plug in because of its high insertion force, and was costly to operate… PowerRail Distributes Redundant Power to Quick-Plug Option ModulesOur customer’s process control system used a sheet-metal bus bar with hard-wired power distribution to the various control modules. This system was unreliable and made changing the various…
dataMate™ High-Speed Copper TransceiverFor companies already heavily invested in copper infrastructure, the high costs of 1-gigabit optical converters created a need for a copper version that could handle short distances. Early copper alternatives were… Smart Transceiver Direct Attach CablesAs 10 gigabit optical transceivers and cables became a costly data system solution due to related distances and installation overheads, the need for an economical option arose… Data Center Cabling InfrastructureA major co-location data center company experienced multiple outages of their Storage Area Network (SAN), costing the company more than $3 million over a four-month period. The customer's network… Fiber Optic Pro-Slide ConnectorManufacturers of patch panels and switch equipment made their products highly dense to increase the number of ports in the smallest possible footprint, creating problems for cable support… DC Series Cabinets for Organizing Cable InfrastructureA major financial services company located in the Dallas area approached CTI with cabling-infrastructure storage problems. The majority of their cabling was stored in an open rack system…
Printed Ink Fuel-Level SensorsThe automotive industry was searching for an alternative method to measure fuel levels, replacing the previous standard of wire-wound resistor technology. The wire-wound system no longer met… Through-Wall Material-Level SensingMany of Methode’s vending-machine customers expressed a growing need to accurately detect inventory levels of coffee beans and sugar in their consumer-facing dispensing equipment… Individual-Patient Medical Fluid BagsPatients lacking incontinence control expressed the need to be notified when bags were nearing full capacity. Our sensor team designed semi-disposable, through-wall fluid detection sensors… Wedge-Brake Sensing SolutionThe automotive industry needed to measure the elastic deformation of the brake caliper, which is used to calculate the normal actuation force of the brake. To accomplish this… Torque, Speed and Direction Measurement for Light Electric VehiclesApproached by an LEV bike manufacturer, Methode was asked to create a single device that enhanced the quality of torque measurement, while adding the ability to measure speed and direction… Measuring the Load on the Forks of a Propelled Lift TruckMethode was tasked with developing a way to measure a load being lifted by the forks of a lift tuck. The first challenge was to determine the point on the fork where the load could be measured… Biometric Sensor for Vehicle PersonalizationToday’s vehicles are highly complex in terms of both features and user interfaces. Methode sought to design a system that would personalize vehicles for each driver. The system also allows… LevelGuard Home Sump ControlsDissatisfied with industry standard float switches, homeowners requested a more reliable means of preventing basement flooding. Methode’s design team addressed owners’ concerns and developed…
Solid-State Control Panel for Kia MotorsKia Motors approached Methode to create a new, in-car infotainment system to debut at the 2010 Consumer Electronics Show (CES). The goal was to transform the automobile’s… Ford Electronic Finish PanelsThe MyFord™ driver-connect technology project began after Ford thoroughly reviewed the current interior design and limitations, considering new and emerging technologies available… Wedge-Brake Sensing SolutionThe automotive industry needed to measure the elastic deformation of the brake caliper, which is used to calculate the normal actuation force of the brake. To accomplish this… Torque, Speed and Direction Measurement for Light Electric VehiclesApproached by an LEV bike manufacturer, Methode was asked to create a single device that enhanced the quality of torque measurement, while adding the ability to measure speed and direction… Biometric Sensor for Vehicle PersonalizationToday’s vehicles are highly complex in terms of both features and user interfaces. Methode sought to design a system that would personalize vehicles for each driver. The system also allows… Heavy Copper PCBs in Automotive ApplicationsElectric Vehicle (EV) inverters represent one of the most demanding potential applications for Heavy Copper PCBs. EV batteries use high-power inverters to generate three-phase power for the AC…
Implementation of Innovative User Interface SolutionsOne of the world’s leading manufacturers of industrial cranes saw their competition gradually adding new features to their products to improve safety and usability… Measuring the Load on the Forks of a Propelled Lift TruckMethode was tasked with developing a way to measure a load being lifted by the forks of a lift tuck. The first challenge was to determine the point on the fork where the load could be measured… Laminated Bus Bars Meet Stringent Demands of Locomotive Traction DrivesWith demands such as temperature extremes, shock and vibration and surge testing with tens of thousands of Amperes, electric-powered locomotives have a heavy electrical load requirement. The customer also needed assurance…
High Resolution Touch Screen for White Goods IndustryOne of the world's largest white-goods OEMs approached TouchSensor™ to design a user interface with consumer electronics-like performance for their premium brand’s new wall oven Next-Generation Biometric Access Control and Time and Attendance TerminalsA potential customer's existing range of products did not significantly stand out from the competition or adequately project the quality and functionality they offered Beverage Dispensing User Interface for Food Service IndustryThe customer’s technical team was intrigued by TouchSensor’s software-free TS100 field-effect touch technology. Capable of being mounted on standard printed circuit board material…
The Development of Extreme Copper TechnologyMethode's partner, UPE, developed the Extreme Copper PCB technology as a result of a customer’s need to handle very high-current values on a board containing small surface-mount devices…
Long Power Cable for Hydrogen Fuel CellsWhen a customer asked us to design a power transmission system for field installations, in lieu of a rigid bus bar our engineers turned to Methode’s Parallel Power Cable for its flexibility…
dataMate™ High-Speed Copper TransceiverFor companies already heavily invested in copper infrastructure, the high costs of 1-gigabit optical converters created a need for a copper version that could handle short distances. Early copper alternatives were… Data Center Cabling InfrastructureA major co-location data center company experienced multiple outages of their Storage Area Network (SAN), costing the company more than $3 million over a four-month period. The customer's network… Fiber Optic Pro-Slide ConnectorManufacturers of patch panels and switch equipment made their products highly dense to increase the number of ports in the smallest possible footprint, creating problems for cable support… DC Series Cabinets for Organizing Cable InfrastructureA major financial services company located in the Dallas area approached CTI with cabling-infrastructure storage problems. The majority of their cabling was stored in an open rack system… Advanced Mainframe Computer Power DistributionA team of designers from a major computer company needed to distribute power to numerous points within a large computer system. They desired a cost-effective solution that offered… Improved Telecommunications Power SystemsA telecommunications power distribution manufacturer required an improved fuse panel that would increase their system rating from 15A to 20A; giving them a competitive advantage… Telecommunication Data Router AssemblyA major telecommunications company approached Methode for design assistance on a new router system. The mechanical layout required an innovative manufacturing method to produce a power… Pluggable High-Power Distribution System Minimizes Server DowntimeMethode was approached by a high-end server customer. The servers process and store data for financial institutions and credit-card companies. Because any server downtime is very costly for this customer, Methode engineers were tasked… Bus Bar Solution for Misalignment in Scalable Server SystemThe customer desired a scalable design that would allow them to plug in modules to increase the capacity of their high-end server. The system operates at a very low DC voltage and thus a bus bar with minimal voltage drop was critical…
Individual-Patient Medical Fluid BagsPatients lacking incontinence control expressed the need to be notified when bags were nearing full capacity. Our sensor team designed semi-disposable, through-wall fluid detection sensors… Laminated and Powder Coated Bus Bars for Medical EquipmentLaminated bus bars are utilized for their space-saving, high frequency, high current capabilities and ability to conform to the specific application architecture. The power is coupled to electrolytic… |
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