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“Love It” – Farebox Sustainment
Aaron Lawson
PSI Repair Services, Inc., Director of Engineering
Livonia, Michigan
• Independent Service Provider(ISP) Capability
• Analyze Current State
• Propose Best Solutions
– Upgrades to Existing Components
– Support for Obsolete Components
• Improved Reliability and Support
Key Presentation Take-Aways
ISP CapabilitiesDesign Services
2D drawings
Production unit
3D rendering
Mechanical Design Electronic Design
Schematic design
and
reverse engineering
PCB layout
Production unit
WHAT TO LOOK FORSustainment Services
Repair
• Diagnose component failures
• Replace faulty and degraded components
• Test and confirm proper operation
Upgrade
• Perform Root Cause Analysis on failures
• Improve design, lessen or eliminate failure modes
• Assemble and test upgrade design, repeat if necessary
Manufacture New
• Reverse engineer sample; Review performance requirements
• Develop engineering documents
• Manufacture and test first article and production units
Root Cause Analysis – Why?
Addresses the root cause of failure, not just the symptoms
• Faulty or weak components
• External causes, e.g. power or environmental issues
• Improperly designed circuits, underrated components
Why RCA Is So Critical to Agency Budgets
• Extend MTBF (Mean Time Between Failures)
• Save LABOR costs
• Saves MATERIAL costs
• Prevent DOWNTIME
• Drives you to the OPTIMAL solution
• Avoid major RETROFITS or overhauls
• Prevent CATASTROPHIC failures before they happen
Why Improve vs. Replace?
• Increased reliability rather than simply replacing
• Addresses actual root cause of failures; corrects
the weak link
• Utilize existing inventory vs. buying new
• Prevents expensive retrofit costs
• Carry less inventory due to extended MTBF
Battery Charger – Under Rated Transformer
• Higher Power Transformer and Custom Adapter Board
• Higher Voltage Metal Oxide Varistors (MOVs)
• Replace all high failure parts including electrolytic
capacitors, voltage regulators and resistors
Battery Charger UpgradeCase Study
ORIGINAL –Back Plane
• Wire wrap design to connectors
• Vibration results in failure
• Difficult to repair
• Intermittent connections
• End of life
NEW–Back Plane
• Copper routed in PCB
• Flex circuits to outside connector
• Removal of vibration failure
• Easier to repair
• Current Design
Wire Wrap to Circuit Board UpgradeCase Study
Upgraded Circuit Board AssemblyCase Study
ORIGINAL
• Four board assembly
• Many failure prone connections
• Soldered jumper wires between boards
• Obsolete optocoupler
NEW DESIGN
• Single board solution
• Utilizes flexible circuit traces
• Eliminates over 100 connections
• Faster more accurate switching waveforms
• Current generation optocoupler
Power Supply Drop In ReplacementCase Study
High Failure Power Supply
• Quasi resonant controller to reduce switching losses
• Planar magnetics for lower losses
• Skip cycle mode for low standby power
• Cycle by cycle over current protection
• Hiccup mode for continuous overload protection
• Provided as a Kit or Service
• High Failure Original Motor
• Contamination
• Large Maintenance Expense
• Drop in Upgrade Kit
• Reduction in Failure Rates
Farebox Bill Transport UpgradeCase Study
• Tap Covers
• Brass Rollers
• Rubber Print Tires
• Axles
Printer Mechanical ComponentsCase Study
High Failure, Obsolete Printer Parts
• Cost Savings
• Replace only what is necessary
• New Fare system is the most
expensive option
• Known Reliability with Existing System
• Engineering Services
Sustainment ServicesIn Summary
Questions?
Aaron Lawson Director of Engineering
(734)558-7688
Contact:
Richard AldereteAccount Manager
(512)560-0021
