Improving the assembly of medical beds

What is the context and application of the customer? ‍

The customer, a manufacturer of medical equipment, produces hospital beds with adjustable mechanisms. These mechanisms include metal axles equipped with machined grooves, in which two circlips are inserted to hold the parts in position. This system is used for the joints that allow the adjustment of the height, the inclination or the supports of these beds.

Although functional, this system had several limitations:

• Assembly complexity: The installation of circlips requires specific tools and extends the assembly time.
• High cost: Each metal shaft machined with grooves, combined with the circlips, represents an expensive solution in terms of materials and machining.
• Reliability issues: During repeated handling or under heavy loads, the circlips could sometimes come loose, compromising stability and safety.

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What was the customer's fixing solution before coming to see us?

The solution consisted of a standard metal shaft with two machined grooves, into which two circlips fit to hold the components in place. However, this configuration proved to be expensive and impractical, in particular because of assembly defects and the risks of mechanical failure.

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What studies have we done?

Analysis of the problem

We worked closely with the client to understand their needs and the technical constraints of medical beds. The main areas of reflection were:

• Cost optimization: Reduced manufacturing and assembly costs.
• Improving safety: Elimination of the risks of detaching the circlips.
• Simplification of assembly: Reduction in the steps and tools required for assembly

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Laboratory testing and validation

We conducted several comparative tests between the existing system (axis + rings) and our recommended solution. These tests included:

• Pull-out resistance.
• Staying in position under dynamic load.
• Durability after several cycles of use.

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What recommendation did we make?

We proposed a fluted pin as a replacement for all three parts (pin + 2 circlips). This solution offers numerous advantages:

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• Elimination of circlips: The fluted pin guarantees perfect support without the need for additional elements.
• Cost reduction: Fewer parts, no groove machining, and a simplified manufacturing process.
• Fast and intuitive assembly: La pin can be installed by simple insertion, without specific tools.
• Increased reliability: The splines prevent any unwanted rotational or translational movement.

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What are the quantifiable benefits for our customer?

Thanks to this solution, the customer was able to see:

• One reduction in production costs by 27% by mechanism.
• One 76% reduction in assembly time, thus increasing the production rate.
• A significant improvement in safety and reliability medical beds, reducing the returns associated with this adjustment mechanism by 86%.

Our solution allowed the customer to remain competitive in a demanding market while strengthening the quality of its products.

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