Multifunctional self-adaptive PogoPin module and mechanical self-calibration assembly process thereof

Abstract

The invention relates to the technical field of electronic connectors, and discloses a multifunctional self-adaptive PogoPin module and a mechanical self-calibration assembly technology thereof.The multifunctional self-adaptive PogoPin module comprises a needle tube, the inner wall of the needle tube is provided with a positioning clamping ring, a damping block and a dustproof piece, the outer wall of the positioning clamping ring is driven to slide to form a connecting assembly, the positioning clamping ring is internally provided with a limiting groove, and the limiting groove is matched with the damping block. The bottom end of the connecting assembly is fixedly connected with a first spring, the outer wall of the first spring is slidably connected to the outer wall of the damping block, the outer wall of the first spring is fixedly connected with a buffer gasket, and the outer wall of the buffer gasket is fixedly connected to the inner bottom wall of the needle tube. Axial buffering is achieved through the buffering gasket at the bottom of the needle tube, broadband vibration is restrained through gradient hardness design of the radial shape memory polyurethane damping block, meanwhile, the wedge-shaped flow guide groove has the heat dissipation and lubricating functions, abrasion between the probe and the needle tube is reduced, an omnidirectional and multifunctional vibration restraining and protecting system is formed, and the service life of the probe is prolonged. And the limitation of a traditional single-function structure is broken through.

Description

Technical Field

[0001] The present invention relates to the technical field of electronic connectors, in particular to a multifunctional adaptive PogoPin module and a mechanical self-calibration assembly process thereof. Background Art

[0002] As electronic devices accelerate their evolution towards miniaturization and high density, PogoPin spring probes, as core components of precision electrical connections, have been deeply applied in high-reliability fields such as automotive electronics, industrial control, and wearable devices. As the types of electronic devices continue to increase, interface specifications have also become more diverse. In order to ensure good electrical connections, a multifunctional adaptive PogoPin module is needed.

[0003] Traditional PogoPin modules typically utilize a basic structure consisting of a needle tube, a spring of equal diameter, and a probe, relying on the spring's elasticity to maintain contact. Traditional axial spring designs only provide unidirectional elastic compensation and lack radial restraint. This leads to significant fluctuations in contact resistance under high-frequency vibration, resulting in unstable signal transmission. Under complex vibration conditions, the probe head can experience radial deflection, reducing the actual contact area. This micro-displacement can cause nonlinear fluctuations in contact impedance, degrading the eye diagram quality of high-speed digital signals and even triggering critical bit error rate alarms. Summary of the Invention

[0004] In response to the shortcomings of the existing technology, the present invention provides a multifunctional adaptive PogoPin module and its mechanical self-calibration assembly process, which solves the problem that the traditional single spring can only provide one-way elastic compensation and lacks radial constraint limitations.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solutions: A multifunctional adaptive PogoPi module includes a needle tube, the inner wall of which is provided with a positioning clip, a damping block and a dustproof sheet, and a connecting component that drives the outer wall of the positioning clip to slide. A limiting groove is provided inside the positioning clip, and the bottom end of the connecting component is fixedly connected to a first spring, the outer wall of the first spring is slidably connected to the outer wall of the damping block, the outer wall of the first spring is fixedly connected to a buffer washer, and the outer wall of the buffer washer is fixedly connected to the inner bottom wall of the needle tube.

[0006] By adopting the above technical solution: the bottom buffer washer realizes axial buffering, the radial shape memory polyurethane damping block suppresses broadband vibration through gradient hardness design, and the wedge-shaped guide groove has heat dissipation and lubrication functions, forming an omnidirectional, multi-functional vibration suppression and protection system, breaking through the limitations of traditional single-function structure.

[0007] Preferably, the connecting assembly includes a probe, the outer wall of the probe is slidably connected to the outer wall of the positioning clamp, the outer wall of the probe is fixedly connected to the limiting block, and the bottom end of the probe is fixedly connected to the outer wall of the first spring.

[0008] Preferably, the outer wall of the limit block is slidably connected to the inner wall of the limit groove, the outer wall of the limit block is slidably connected to the outer wall of the positioning clamp, and the outer wall of the limit block is slidably connected to the inner wall of the needle tube.

[0009] Preferably, a spiral guide groove and conical micropores are provided inside the probe, and the spiral guide groove and conical micropores are used to actively remove dust from the contact surface during the process of plugging and unplugging the probe. The outer wall of the probe is fixedly connected to the inside of the dustproof sheet, and a one-way dust guide flap is provided at the end of the dustproof sheet, and its opening and closing angle is 15°-30°, which is used to form a high-speed airflow to blow away dust through the Venturi effect during the plugging and unplugging process.

[0010] Preferably, the surface of the damping block is provided with a wedge-shaped guide groove, which is used for radial vibration constraint, heat dissipation and lubrication; the circumferential protrusions of the damping block are evenly distributed, with a positioning accuracy of ±0.01mm, and the radial constraint stiffness is adjusted through the shape memory effect when the temperature changes.

[0011] Preferably, the surface of the probe 3 is provided with a gradient coating, and the gradient coating is sequentially from the inside to the outside: a copper layer directly electroplated on the probe 3 substrate; a nickel-phosphorus alloy layer chemically deposited on the surface of the copper layer; and a gold-plated layer covering the nickel-phosphorus alloy layer, and each coating presents a continuous and dense laminated structure.

[0012] Preferably, the interior of the probe is fixedly connected to a limiting cylinder, the interior of the limiting cylinder is slidably connected to a clamping block, a second spring is provided inside the limiting cylinder, one end of the second spring is fixed to the clamping block, and the other end abuts against the inner wall of the limiting cylinder.

[0013] Preferably, a mechanical self-calibration assembly process of a multifunctional adaptive PogoPi module is used for the multifunctional adaptive PogoPi module, and the method comprises the following steps: S1. Spring preload adjustment: Place the first spring into the lower section of the needle tube, slide the stopper on the probe over the stopper groove, press and rotate the probe until the spring is compressed to 2.8 mm, and secure with the positioning ring. S2. Damping block assembly: Use a precision jig to embed the damping block into the inner wall of the needle tube, ensuring that the wedge-shaped guide groove is aligned with the guide groove in the probe; S3, gradient coating processing: the probe is subjected to electroplating of copper, chemical plating of nickel-phosphorus alloy and gold plating in sequence, with a total coating thickness of 6μm; S4. Component pre-assembly: put the needle tube into place, install the damping block, put in the first spring, insert the probe, and finally install the positioning clamp ring, and manually calibrate to the preset scale; S5. Ultrasonic welding: Weld the contact area between the positioning clamp and the needle tube. The welding power is 200W and the time is 0.3s. S6. Attach the buffer gasket: Use a vacuum adsorption device to attach the buffer gasket to the bottom of the needle tube with a bonding force of 1.5-2N.

[0014] Preferably, the damping block in S2 is embedded with shape memory polyurethane material, which has a Shore hardness of 60D-80D and softens in a high temperature environment to absorb impact energy, the temperature being ≥80°C.

[0015] Preferably, the damping block is made of silicone rubber material, wherein the silicone rubber Shore hardness is 55A; the head of the probe is set as a serrated dust scraping protrusion, which has a height of 0.08mm and a spacing of 0.3mm; a snap-on limit ring is used to limit the probe, wherein the thickness is 0.2mm and there are 3 elastic claws; the gradient coating on the surface of the probe reduces the thickness of the chemical nickel-phosphorus alloy layer to 0.5μm, and at the same time increases the thickness of the gold plating layer to 2.5μm.

[0016] Working Principle: When using the PogoPin module, first insert the probe into the corresponding connector, which squeezes the probe to make it slide in the needle tube. The probe then compresses the first spring, causing it to contract and drive the needle tube to slide. This sliding action squeezes the air in the needle tube, causing the spiral guide groove in the needle tube to generate centrifugal force to throw off dust. The conical micropores distributed in the annular array use the Venturi effect to form a high-speed airflow purge, which, combined with the elasticity of the dust guide groove end, creates a three-level protection system of "dust prevention-air diversion-purge", significantly improving reliability in dusty environments. When the probe is connected to the connector, the corresponding connector will squeeze the block to make it slide in the limit cylinder, and then squeeze the second spring to make it contract. At this time, under the rebound action of the second spring, the block will conflict with the corresponding connector, thereby assisting the connection between the probe and the corresponding connector.

[0017] The present invention provides a multifunctional adaptive PogoPin module and its mechanical self-calibration assembly process. It has the following beneficial effects: 1. In this invention, a silicone cushioning gasket is used at the bottom of the needle tube to absorb axial impact energy through elastic deformation, effectively reducing damage to internal components caused by transient overloads. A shape-memory polyurethane damping block is configured radially to provide rigid support at room temperature through phase change characteristics, softening and absorbing impact energy at high temperatures. At the same time, the wedge-shaped guide groove on the inner wall of the needle tube accelerates heat dissipation by guiding airflow and stores grease, reducing wear between the probe and the needle tube. These three elements work together to create a full-dimensional vibration suppression system in the axial, radial, and circumferential directions, supplemented by dynamic heat dissipation and lubrication, breaking through the limitations of the traditional single spring buffer structure.

[0018] 2. In the present invention, when the probe is plugged in or out, the spiral guide groove of the probe generates centrifugal force to throw away dust, and the conical micropores distributed in the ring array use the Venturi effect to form high-speed airflow for sweeping, which cooperates with the elastic dustproof sheet at the end of the dust guide groove to construct a three-level protection of "dustproof-guiding-sweeping", which significantly improves the reliability in dusty environments.

[0019] 3. In the present invention, a gradient coating of copper plating, chemical nickel-phosphorus alloy plating and gold plating is used, which effectively improves the oxidation resistance and bonding strength of the coating while ensuring conductivity, reduces costs, greatly improves the service life and reliability of the probe, and effectively enhances the bonding strength between the coating and the probe substrate.

[0020] 4. In the present invention, the shape memory polyurethane damping block adjusts its performance according to temperature changes, provides radial constraint stiffness at room temperature, softens and absorbs impact energy at high temperature, effectively protects the probe and related components from impact damage, realizes the adaptive function of high temperature buffering, and is suitable for complex environments with large temperature differences.

[0021] 5. In the present invention, when the probe is connected to the connector, the corresponding connector will squeeze the block to make it slide in the limit cylinder, and then squeeze the second spring to make it contract. At this time, under the rebound action of the second spring, the block will conflict with the corresponding connector, thereby assisting the connection between the probe and the corresponding connector, thereby achieving the effect of ensuring the stability of the electrical connection and the firmness of the mechanical connection. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 A three-dimensional diagram of a multifunctional adaptive PogoPi module of the present invention; Figure 2 A schematic diagram of a probe of a multifunctional adaptive PogoPi module of the present invention; Figure 3 A schematic diagram of a positioning clip for a multifunctional adaptive PogoPi module of the present invention; Figure 4 A schematic diagram of a limit block of a multifunctional adaptive PogoPi module of the present invention; Figure 5This is a schematic diagram of the first spring of a multifunctional adaptive PogoPi module of the present invention; Figure 6 A schematic diagram of a buffer washer of a multifunctional adaptive PogoPi module of the present invention; Figure 7 A schematic diagram of a card block of a multifunctional adaptive PogoPi module of the present invention; Figure 8 This is a process flow chart for the mechanical self-calibration assembly of a multifunctional adaptive PogoPi module of the present invention.

[0023] Among them, 1. needle tube; 2. positioning clamp; 3. probe; 4. limit block; 5. limit groove; 6. first spring; 7. buffer washer; 8. damping block; 9. wedge-shaped guide groove; 10. spiral guide groove; 11. conical micropore; 12. limit cylinder; 13. clamping block; 14. second spring; 15. connecting assembly; 16. dustproof sheet. DETAILED DESCRIPTION

[0024] The following will clearly and completely describe the technical solutions of the present invention in conjunction with the accompanying drawings. Obviously, the embodiments described are only some of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts are within the scope of protection of the present invention.

[0025] Please see the attached Figure 1 -Attached Figure 4 An embodiment of the present invention provides a multifunctional adaptive PogoPi module, including a needle tube 1. The inner wall of the needle tube 1 is provided with a positioning clip 2, a damping block 8 and a dustproof sheet 16. The outer wall of the positioning clip 2 is driven to slide with a connecting component 15. A limiting groove 5 is provided inside the positioning clip 2. The bottom end of the connecting component 15 is fixedly connected to a first spring 6. The outer wall of the first spring 6 is slidably connected to the outer wall of the damping block 8. The outer wall of the first spring 6 is fixedly connected to a buffer washer 7. The outer wall of the buffer washer 7 is fixedly connected to the inner bottom wall of the needle tube 1.

[0026] Specifically, the needle tube 1 is the main structure of the module, which provides mechanical support and space accommodation. The needle tube 1 supports and fixes the positioning clamp 2, and the positioning clamp 2 supports the limiting connection component 15. The limiting groove 5 constrains the movement range of the connection component 15, thereby preventing excessive displacement of the probe 3. The first spring 6 provides axial elastic support to ensure that the probe 3 automatically resets after plugging and unplugging. The damping block 8 absorbs radial vibration energy and improves the buffering performance of the module. The buffer gasket 7 absorbs axial impact energy and protects internal components from instantaneous overload damage. The dustproof sheet 16 blocks external dust from entering the module and improves environmental adaptability.

[0027] Please see the attached Figure 2 -Attached Figure 6 The connecting assembly 15 includes a probe 3, the outer wall of the probe 3 is slidably connected to the outer wall of the positioning clamp 2, the outer wall of the probe 3 is fixedly connected to the limiting block 4, and the bottom end of the probe 3 is fixedly connected to the outer wall of the first spring 6; the outer wall of the limiting block 4 is slidably connected to the inner wall of the limiting groove 5, the outer wall of the limiting block 4 is slidably connected to the outer wall of the positioning clamp 2, and the outer wall of the limiting block 4 is slidably connected to the inner wall of the needle tube 1; a spiral guide groove 10 and a conical microhole 11 are provided inside the probe 3, and the spiral guide groove 10 and the conical microhole 11 are used to actively remove dust from the contact surface during the insertion and removal of the probe 3. The outer wall of the probe 3 is fixedly connected to the inside of the dustproof sheet 16, and the end of the dustproof sheet 16 is provided with a There is a one-way dust guide flap with an opening and closing angle of 15°-30°, which is used to form a high-speed airflow to blow away dust through the Venturi effect during the plugging and unplugging process; the surface of the damping block 8 is provided with a wedge-shaped guide groove 9, which is used for radial vibration constraint, heat dissipation and lubrication; the circumferential protrusions of the damping block 8 are evenly distributed, with a positioning accuracy of ±0.01mm, and the radial constraint stiffness is adjusted through the shape memory effect when the temperature changes; the surface of the probe 3 is provided with a gradient coating, and the gradient coating is from the inside to the outside: a copper layer directly electroplated on the probe 3 substrate; a nickel-phosphorus alloy layer chemically deposited on the surface of the copper layer; a gold-plated layer covering the nickel-phosphorus alloy layer, and each coating has a continuous and dense laminated structure.

[0028] Specifically, under the connection of the limit block 4, the needle tube 1 supports the limit probe 3 through the positioning clamp 2, wherein the limit block 4 can just slide through the limit groove 5, and after rotating the probe 3, it can be limited in the needle tube 1 by the positioning clamp 2. At the same time, the limit block 4 can also ensure the guidance of the axial movement of the probe 3, and the positioning clamp 2 also ensures that the probe 3 moves along the preset path during the plugging and unplugging process. The spiral guide groove 10 in the probe 3 uses centrifugal force to throw off the attached dust during plugging and unplugging, and the conical micropore 11 generates a high-speed airflow of ≥8m / s through the Venturi effect, thereby playing an active purging role. The role of the contact surface; the surface of the probe 3 contains a gradient coating, in which the copper layer is the base, which can provide a good conductive foundation; the middle nickel-phosphorus alloy layer not only further enhances the conductivity, but also plays a transitional role, making the coating and the substrate more tightly bonded; the outer gold layer has excellent conductivity and oxidation resistance, which ultimately makes the overall contact resistance of the probe 3 stably controlled below 5mΩ, and the salt spray resistance reaches more than 72 hours, which greatly improves the service life and reliability of the probe 3, and effectively enhances the bonding force between the coating and the probe 3 substrate, wherein the damping block 8 is made of shape memory polyurethane material and has unique performance characteristics. Under normal temperature conditions, this material can provide precise radial constraint stiffness for the probe 3, ensuring a positioning accuracy of ±0.01mm, so that the probe 3 always maintains a precise radial position during operation; when the ambient temperature rises to 80°C or above, the shape memory polyurethane will change its properties and soften, at which time it can efficiently absorb impact energy and effectively protect the probe 3 and related components from impact damage; in addition, circumferential protrusions are evenly distributed on the surface of the damping block, which can suppress radial vibration when the probe 3 is working, reducing the adverse effects of vibration on measurement accuracy and stability of the probe 3; among them, the wedge-shaped guide groove 9 can, on the one hand, guide the airflow in an orderly manner, so that the airflow flows smoothly around the probe 3, thereby taking away the heat generated by friction during operation of the probe 3, effectively reducing the temperature rise caused by frictional heat, ensuring that the probe 3 operates in a suitable temperature environment, and maintaining the stability of its performance; on the other hand, the wedge-shaped guide groove 9 can also store a certain amount of grease. When the probe 3 and the inner wall of the needle tube 1 move relative to each other, the grease can continue to play a role, reducing wear between the two and extending the service life of the probe 3 and the needle tube 1.

[0029] Please see the attached Figure 1 and attached Figure 7 The interior of the probe 3 is fixedly connected to a limiting cylinder 12, and the interior of the limiting cylinder 12 is slidably connected to a clamping block 13. A second spring 14 is provided inside the limiting cylinder 12, and one end of the second spring 14 is fixed to the clamping block 13, and the other end abuts against the inner wall of the limiting cylinder 12.

[0030] Specifically, when the probe 3 is connected to the connector, the corresponding connector plays the role of squeezing the block 13 to make it slide in the limiting cylinder 12, wherein the limiting cylinder 12 plays the role of supporting the limiting block 13, thereby effectively preventing the block 13 from deviating due to uneven force or shaking during the sliding process, ensuring that it slides stably along the predetermined track, and then playing the role of squeezing the second spring 14 to make it contract. At this time, under the rebound action of the second spring 14, the block 13 plays the role of conflicting with the corresponding joint, thereby assisting the probe 3 to connect with the corresponding connector, thereby ensuring the stability and reliability of the connection.

[0031] Please see the attached Figure 1 -Attached Figure 8 A mechanical self-calibration assembly process for a multifunctional adaptive PogoPi module is provided, and is used for the multifunctional adaptive PogoPi module described above. The method comprises the following steps: S1. Spring preload adjustment: Place the first spring 6 into the lower section of the needle tube 1. Slide the stopper 4 on the probe 3 over the stopper groove 5. Press and rotate the probe 3 until the spring is compressed to 2.8 mm. Secure it with the positioning ring 2. S2. Assembly of the damping block 8: Use a precision jig to embed the damping block 8 into the inner wall of the needle tube 1, ensuring that the wedge-shaped guide groove 9 is aligned with the guide groove in the probe 3; S3, gradient coating processing: the probe 3 is subjected to copper electroplating, chemical nickel-phosphorus alloy plating and gold plating in sequence, with a total coating thickness of 6 μm; S4. Component pre-assembly: sequentially place the needle tube 1 in place, install the damping block 8, insert the first spring 6, insert the probe 3, and finally install the positioning clamp 2, and manually calibrate to the preset scale; S5, ultrasonic welding: welding the contact part between the positioning clamp 2 and the needle tube 1, with a welding power of 200W and a time of 0.3s; S6. Fitting of the buffer gasket 7: Use a vacuum adsorption device to fit the buffer gasket 7 to the bottom of the needle tube 1 with a fitting force of 1.5-2N; the embedding of the damping block 8 in S2 adopts shape memory polyurethane material with a Shore hardness of 60D-80D, and softens in a high temperature environment ≥80℃ to absorb impact energy, the temperature is ≥80℃.

[0032] Please see the attached Figure 1 -Attached Figure 8 The damping block 8 is made of silicone rubber with a Shore hardness of 55A. The head of the probe 3 is provided with a serrated dust scraping protrusion with a height of 0.08 mm and a spacing of 0.3 mm. The probe 3 is limited by a snap-on limit ring with a thickness of 0.2 mm and 3 elastic claws. The gradient coating on the surface of the probe 3 reduces the thickness of the chemical nickel-phosphorus alloy layer to 0.5 μm, while increasing the thickness of the gold plating layer to 2.5 μm.

[0033] Specifically, in industrial environments with small temperature fluctuations and cost sensitivity, using silicone rubber with a Shore hardness of 55A instead of shape memory polyurethane material can reduce costs and increase the temperature resistance of the damping block from 80°C to 150°C, better adapting to the high temperature requirements of the industrial environment, thereby meeting the cost control requirements of industrial scenarios and enabling the module to work stably in higher temperature environments; in scenarios with large dust particles such as mining machinery and construction equipment, the spiral guide grooves and conical micropores are replaced with serrated dust scraping protrusions, and dust can be removed through plug-in friction, thereby enhancing the self-cleaning ability of the module in harsh environments, and effectively preventing problems such as poor contact caused by dust accumulation, thereby improving the reliability of the module in dusty environments. The new product improves the reliability of the module, extending the service life of the module and reducing repair and replacement costs caused by dust. In consumer electronics and low-precision industrial connectors, a 0.2mm thick snap-on retaining ring with three elastic claws replaces the positioning ring. This simplifies the assembly process and reduces the reliance on high-precision assembly equipment. This can shorten assembly time, improve production efficiency, and reduce production costs. It is particularly suitable for cost-sensitive applications with low precision requirements. In short-term use or low-corrosive environments, the thickness of the electroless nickel-phosphorus alloy layer is reduced to 0.5μm, while the gold layer is increased to 2.5μm. The plating structure is adjusted to balance cost and performance. This ensures the conductivity and oxidation resistance of the probe while reducing production costs. Increasing the gold layer thickness improves contact performance and reduces contact resistance, while thinning the electroless nickel-phosphorus alloy layer effectively saves material costs. It is suitable for short-term use or low-corrosive environments, meeting the needs of different usage scenarios.

[0034] A multifunctional adaptive PogoPi module in this embodiment, when in use, first inserts the probe 3 into the corresponding connector, which squeezes the probe 3 to make it slide in the needle tube 1, and then squeezes the first spring 6 by the probe 3 to make it contract, which drives the dustproof sheet 16 to slide. At this time, the sliding of the dustproof sheet 16 squeezes the air in the needle tube 1, and then the spiral guide groove 10 in the needle tube 1 generates centrifugal force to throw dust. The conical micropores 11 distributed in the annular array use the Venturi effect to form a high-speed airflow purge, which cooperates with the elastic dustproof sheet 16 at the end of the dust guide groove to construct a "dust-proof-flow-purge" three-level protection, which can significantly improve the reliability in dusty environments; When the probe 3 is connected to the connector, the corresponding connector will squeeze the block 13 to make it slide smoothly in the limiting cylinder 12. The limiting cylinder 12 provides good guidance and limiting effect on the block 13, preventing the block 13 from deflecting. As the block 13 slides, it squeezes the second spring 14, causing it to contract evenly, storing elastic potential energy. When the probe 3 and the connector approach the predetermined connection position, the second spring 14 rapidly expands under the action of the rebound force, pushing the block 13 into close contact with the positioning hole on the connector, generating a firm clamping force, helping the probe 3 and the corresponding connector to achieve a stable and reliable connection, ensuring the stability of the electrical connection and the firmness of the mechanical connection.

[0035] Example 1: High-durability plug-in life optimization solution 1. Technical Solution 1. Spring material and structure optimization Nickel-titanium shape memory alloy (Ni-TiSMA) is used as the material of the first spring (6), with a diameter of 0.3 mm, a preload of 2.8 mm, and a yield strength of ≥1500 MPa.

[0036] The surface of the spring is coated with diamond-like carbon (DLC) coating with a thickness of 0.5μm and a friction coefficient of ≤0.1.

[0037] 2. Improvement of gradient coating process The probe (3) surface gradient coating is as follows: electroplated copper (3 μm) → chemically plated nickel-phosphorus alloy (Ni-P 12%, 1 μm) → pulse electroplated hard gold (2 μm).

[0038] Plating bath parameters: copper electroplating current density 2A / dm 2 , chemical nickel-phosphorus plating temperature is 85°C, and gold plating pulse frequency is 1000Hz.

[0039] 2. Parameter Optimization Basis 1. Shape memory alloy: The phase transition temperature (Af = 50°C) is determined by differential scanning calorimetry (DSC) to ensure high elasticity at room temperature and creep resistance at high temperatures.

[0040] 2. DLC coating: verified by nanoindentation test (ISO14577) with hardness ≥ 20GPa, reducing spring fatigue.

[0041] 3. Implementation Effect Verification Plug and unplug life test (EIA-364-09 standard): Test conditions Existing technology (decay rate) This embodiment (attenuation rate) Improvement 500,000 plug and unplug cycles 15％ <5％ 900％ Summary: This solution significantly reduces the contact resistance attenuation rate through coordinated optimization of materials and coatings, verifying that the high-durability design improves the plug-in life.

[0042] Example 2: Broadband Anti-Vibration Performance Enhancement Solution 1. Technical Solution 1. Damping block structure optimization The shape memory polyurethane damping block (8) is designed to have a gradient hardness (60D for the outer layer and 40D for the inner layer), and the surface wedge-shaped guide groove (9) has an inclination angle of 15°.

[0043] The metal rubber layer and the shape memory alloy mesh (Ni-Ti) are alternately laminated at a thickness ratio of 1:3, with a pre-deformation of 10%.

[0044] 2. Connection component stability design The clearance between the limiting block (4) and the limiting groove (5) is controlled to be ±0.01 mm, and laser polishing is used to reduce the friction coefficient.

[0045] 2. Parameter Optimization Basis 1. Gradient hardness design: Dynamic mechanical analysis (DMA) verifies that the damping loss factor (tanδ) is ≥ 0.3 (10-2000Hz).

[0046] 2. Gap control: Finite element simulation (ANSYS) shows that a gap of ≤0.01mm can suppress the resonance peak.

[0047] 3. Implementation Effect Verification Vibration resistance test (ASTMD3580 standard): Test conditions Existing technology (resistance fluctuation) This embodiment (resistance fluctuation) Improvement 30g full-axis vibration >0.2Ω <0.005Ω 97.5％ Summary: The gradient damping structure and precision limit design effectively suppress broadband vibration and verify the significant improvement of contact resistance stability.

[0048] Example 3: Dust environment adaptability optimization plan 1. Technical Solution 1. Self-cleaning airflow system The probe (3) head is designed with a spiral guide groove (10) (pitch 0.5mm) and a conical microhole (11) (aperture 0.08mm), and the air flow velocity is ≥8m / s.

[0049] The dustproof piece (16) has a one-way dust guide flap with an opening and closing angle of 25 degrees and is made of TPU material (Shore hardness 70A).

[0050] 2. Optimization of dustproof structure The inner wall of the needle tube (1) is sprayed with an oleophobic coating (contact angle ≥ 110°) to reduce dust adhesion.

[0051] 2. Parameter Optimization Basis Verification of Venturi effect: Computational fluid dynamics (CFD) simulation shows that the airflow velocity of the conical micropore is positively correlated with the removal efficiency of dust particle size (≥50μm).

[0052] Oleophobic coating: The surface morphology of the coating was observed by scanning electron microscopy (SEM) to confirm that it had a non-porous structure.

[0053] Implementation effect verification Dust environment test (ISO12103-1A4 level): Test conditions Existing technology (poor contact rate) This embodiment (contact failure rate) Improvement <![CDATA[Dust concentration 5g / m 3 > 12％ 1.5％ 87.5％ Summary: Active airflow purge and oleophobic coating work together to significantly reduce the contact failure rate in dusty environments Example 4: Corrosion-resistant coating optimization solution 1. Technical Solution 1. Improvement of gradient coating process The thickness of the electroless nickel-phosphorus alloy layer was increased to 1.5 μm, the phosphorus content was increased to 14%, and nano-Al 2 O 3 particles (0.1 wt %) were added to the plating solution.

[0054] The gold plating layer adopts pulse electroplating process (duty cycle 30%) and has a thickness of 2.5μm.

[0055] 2. Post-processing process After the coating is completed, vacuum annealing (200℃, 2 hours) is performed to eliminate internal stress.

[0056] 2. Parameter Optimization Basis High-phosphorus nickel-phosphorus alloy: The amorphous structure is confirmed by X-ray diffraction (XRD) analysis, and the corrosion resistance is better than that of low-phosphorus coatings.

[0057] Pulse plating: Electrochemical impedance spectroscopy (EIS) shows that the density of the coating is improved by 30%.

[0058] 3. Implementation Effect Verification Salt spray test (ASTM B117 standard): Summary: The combination of high phosphorus coating and pulse process significantly extends the salt spray resistance time of the coating, verifying the optimization of anti-corrosion performance.

[0059] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A multifunctional adaptive PogoPi module, comprising a needle tube (1), characterized in that: The inner wall of the needle tube (1) is provided with a positioning clamp (2), a damping block (8) and a dustproof sheet (16), and a connecting component (15) is driven to slide on the outer wall of the positioning clamp (2). A limiting groove (5) is provided inside the positioning clamp (2), and the bottom end of the connecting component (15) is fixedly connected to a first spring (6), the outer wall of the first spring (6) is slidably connected to the outer wall of the damping block (8), the outer wall of the first spring (6) is fixedly connected to a buffer washer (7), and the outer wall of the buffer washer (7) is fixedly connected to the inner bottom wall of the needle tube (1).

2. The multifunctional adaptive PogoPi module according to claim 1, characterized in that: The connecting assembly (15) includes a probe (3), the outer wall of the probe (3) is slidably connected to the outer wall of the positioning clamp (2), the outer wall of the probe (3) is fixedly connected to the limit block (4), and the bottom end of the probe (3) is fixedly connected to the outer wall of the first spring (6).

3. The multifunctional adaptive PogoPi module according to claim 2, characterized in that: The outer wall of the limit block (4) is slidably connected to the inner wall of the limit groove (5), the outer wall of the limit block (4) is slidably connected to the outer wall of the positioning clamp (2), and the outer wall of the limit block (4) is slidably connected to the inner wall of the needle tube (1).

4. The multifunctional adaptive PogoPi module according to claim 2, characterized in that: The probe (3) is provided with a spiral guide groove (10) and a conical micropore (11) inside, and the spiral guide groove (10) and the conical micropore (11) are used to actively remove dust from the contact surface during the process of plugging and unplugging the probe (3). The outer wall of the probe (3) is fixedly connected to the inside of the dustproof sheet (16), and the end of the dustproof sheet (16) is provided with a one-way dust guide flap, whose opening and closing angle is 15°-30°, and is used to form a high-speed airflow to blow away dust through the Venturi effect during the plugging and unplugging process.

5. The multifunctional adaptive PogoPi module according to claim 1, characterized in that: The surface of the damping block (8) is provided with a wedge-shaped guide groove (9), and the wedge-shaped guide groove (9) is used for radial vibration constraint, heat dissipation and lubrication; the circumferential protrusions of the damping block (8) are evenly distributed, with a positioning accuracy of ±0.01mm, and the radial constraint stiffness is adjusted through a shape memory effect when the temperature changes.

6. The multifunctional adaptive PogoPi module according to claim 2, characterized in that: The probe (3) is provided with a gradient coating on its surface, and the gradient coating comprises, from the inside to the outside, a copper layer directly electroplated on the probe (3) substrate; a nickel-phosphorus alloy layer chemically deposited on the surface of the copper layer; and a gold-plated layer covering the nickel-phosphorus alloy layer, wherein each coating presents a continuous and dense laminated structure.

7. The multifunctional adaptive PogoPi module according to claim 2, characterized in that: The probe (3) is fixedly connected to a limiting cylinder (12) inside, and a clamping block (13) is slidably connected to the inside of the limiting cylinder (12). A second spring (14) is provided inside the limiting cylinder (12), and one end of the second spring (14) is fixed to the clamping block (13), and the other end abuts against the inner wall of the limiting cylinder (12).

8. A mechanical self-calibration assembly process for a multifunctional adaptive PogoPi module, characterized in that: A multifunctional adaptive PogoPi module according to any one of claims 1 to 7, the method comprising the following steps: S1. Spring preload adjustment: Place the first spring (6) into the lower section of the needle tube (1), slide the limit block (4) on the probe (3) over the limit groove (5), press and rotate the probe (3) until the spring compression amount is 2.8 mm, and fix it with the positioning clamp (2); S2. Assembly of the damping block (8): Use a precision jig to embed the damping block (8) into the inner wall of the needle tube (1), ensuring that the wedge-shaped guide groove (9) is aligned with the guide groove in the probe (3); S3, gradient coating processing: the probe (3) is subjected to electroplating copper, chemical plating nickel-phosphorus alloy and gold plating in sequence, with a total coating thickness of 6 μm; S4, pre-assembly of components: sequentially place the needle tube (1), install the damping block (8), insert the first spring (6), insert the probe (3), and finally install the positioning clamp (2), and manually calibrate to the preset scale; S5, ultrasonic welding: welding the contact portion between the positioning clamp (2) and the needle tube (1), with a welding power of 200W and a time of 0.3s; S6. Attaching the buffer gasket (7): Attach the buffer gasket (7) to the bottom of the needle tube (1) using a vacuum adsorption device with a bonding force of 1.5-2N.

9. The mechanical self-calibration assembly process of a multifunctional adaptive PogoPi module according to claim 8, characterized in that: The damping block (8) in S2 is embedded with a shape memory polyurethane material having a Shore hardness of 60D-80D and softening in a high temperature environment to absorb impact energy, the temperature being ≥80°C.

10. The mechanical self-calibration assembly process of a multifunctional adaptive PogoPi module according to claim 8, characterized in that: The damping block (8) is made of silicone rubber material, wherein the silicone rubber has a Shore hardness of 55A; the head of the probe (3) is set as a serrated dust scraping protrusion, which has a height of 0.08 mm and a spacing of 0.3 mm; a snap-on limit ring is used to limit the probe (3), wherein the thickness is 0.2 mm and there are three elastic claws; the gradient coating on the surface of the probe (3) reduces the thickness of the chemical nickel-phosphorus alloy layer to 0.5 μm, and increases the thickness of the gold plating layer to 2.5 μm.

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