Stamped Steel Power Network Box Bracket for the Automotive Industry

Highlands Diversified Services began this steel power network box bracket project by working with the customer to improve the design. The initial design required four separate stampings be welded together, but the resulting assembly was prone to failure. Using finite element analysis (FEA) and 3-D CAD modeling, we set to work exploring alternative design options. To simplify the process, we developed a two-piece component that relied on resistance welding. The new design eliminated the cost of two additional dies, the processing cost for each part, and two additional welding fixtures. Most importantly, the part passed all integrity testing.

Using grade 50 high-strength low-alloy steel, we manufactured the component using stamping and resistance welding and finished each bracket with a black epoxy coat. The final product measured 8” long, 5” wide, and .060” thick. We upheld a tight tolerance of +/- .005" throughout the process. As a special feature, we included white nut identification for vehicle assembly.

After we had determined that all standards were met, including OEM requirements, we packaged the brackets in a special cell pack. The brackets were then delivered weekly, over the course 5 years, for a total of 225,000 brackets annually. On receipt of the brackets in El Paso Texas and Jarez Mexico, where the power supply was assembled to the network box brackets and shipped back to the USA for installation at the OEM truck assembly plants.  To learn more about this project, please contact Highlands Diversified Services.