Legacy Farebox Sustainment

Aaron Lawson

PSI Repair Services, Inc., Director of Engineering

Livonia, Michigan

• Analyze Current State

• Independent Service Provider(ISP) Capability

• Root Cause Analysis

• Case Studies

Key Presentation Take-Aways

• Environmental Stresses Including:

– High And Low Temperatures

– Vibration

– Shock

– Dust

– Dirt

– Contamination From Currency

• Electrical Conditions Including:

– Transient Voltages

– Intermittent Loss of Power

Harsh Environment

• Obsolescence is common with components expected to last 20-25 years

Obsolescence

• Eliminate Obsolescence with Current Generation Parts• Improve Fault Prevention Techniques• Improve Environmental Specifications• Drop In Replacement; No Modifications Needed• Remove Specific Failure Modes

New Technology

ISP CapabilitiesDesign Services

2D drawings

Production unit

3D rendering

Mechanical Design Electronic Design

Schematic design and reverse engineering

PCB layout

Production unit

Root Cause Analysis – Why?

• Addresses The Root Cause, Not Just The Symptoms

• Faulty Or Weak Components

• Power Or Environmental Issues

• Improperly Designed Circuits

• Underrated Components• Increased Reliability• Corrects The Weak Link

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

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

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

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

Bent Frames

Bill Transport Damage

Worn Gears

Stripped Nylon Gears

Worn Axles

• 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

• Plastic Covers

• Brass Rollers

• Rubber Print Tires

• Axles

Printer Mechanical ComponentsCase Study

High Failure, Obsolete Printer Parts

• Harsh Environment

• Obsolescence Issues Updated with New Technology

• RCA Drives to Solutions

• Repair, Upgrade or Manufacture

• Replace only what is necessary

Legacy Farebox SustainmentIn Summary

Questions?

Aaron Lawson Director of Engineering(734)558-7688alawson.rsi@psi-corp.com

Contact:

Richard AldereteAccount Manager(512)560-0021richard.alderete@psi-corp.com