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CASE STUDY

Actuation Linkage for an Exhaust Gas Recirculation Valve (EGRV)

Overview

A leading supplier of exhaust gas management systems for hybrid vehicles turned to Radial Bearing for a motion control solution that could withstand extreme environmental conditions, rigorous testing standards, and large-scale production demands. This collaboration resulted in a high-performance actuator linkage assembly that exceeded expectations in durability, cost-efficiency, and scalability.

The Challenge

The client’s original linkage design failed under harsh conditions, including high heat, vibration, corrosion, and debris. Specific challenges included:

  • Extreme Operating Temperatures: Components needed to function reliably in high-heat zones of a hybrid exhaust system (up to 575°F).
  • Corrosive Exposure: Steel-on-steel rod ends quickly deteriorated.
  • Cost Sensitivity: High production volumes required a commercially viable solution.
  • Rigorous Validation: Automotive-grade durability testing across multiple geographies added complexity and timeline pressure.
Automotive-grade durability testing across multiple geographies added complexity and timeline pressure.

The Solution

Radial Bearing developed a durable actuator linkage featuring a custom polymer race material that offered excellent high-temperature performance without the cost burden of exotic materials. Key aspects of the solution included:

  • Engineering Innovation: Replaced the legacy steel race with a specially engineered polymer rated for 575°F, ideal for the cooler side of the linkage system.
  • Collaborative Supplier Development: Identified and onboarded a new molding supplier who could meet material and timeline requirements for full PPAP approval.
  • Integrated Design Support: Provided a pre-installed lever assembly, eliminating downstream labor and reducing the customer’s production time.
  • Agile Prototyping: Partnered closely with the OEM’s global engineering teams to produce, iterate, and validate prototypes in both North America and Europe.
  • Scalable Manufacturing: Responded to unanticipated growth, with fast capacity expansion supported by Radial Bearing’s lean, domestic production model.
Partnered closely with the OEM’s global engineering teams to produce, iterate, and validate prototypes in both North America and Europe.

The Results

The final assembly delivered on all fronts: thermal performance, corrosion resistance, cost reduction, and speed to market. As a result:

  • The client achieved improved reliability in a previously failure-prone component.
  • Assembly operations became faster and more efficient with the integrated lever solution.
  • Radial Bearing scaled rapidly to meet demand, without compromising lead time or quality.

This project demonstrates Radial Bearing’s deep expertise in materials engineering, linkage design, and scalable, certified production environments (AS9100, ISO 9001, ITAR). It also highlights our ability to create long-term value as an engineering partner, not just a parts supplier.

Get Started on Your Project

Put reliable control in the hands of the world’s drivers, pilots, and equipment operators with the expertise and support of Radial Bearing. Contact us today to discuss your needs.

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