PCB Backplane Pin Reforming Die for Controlled Multi-Pin Alignment
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Solution Overview
Problem
Current methods for reforming electrical pin connectors in nuclear plant control systems are uncontrolled and inefficient, particularly due to the lack of a convenient tool to restore pins to their original specifications, which is critical for maintaining reliable connections in systems with numerous pins.
Innovation Solution
A pin reforming tool featuring a reforming die assembly with a force applicator and an extension rod, connected to an automatic center punch for controlled force application, and a spring-loaded slide block for precise alignment and movement, allowing for the reforming of multiple pins simultaneously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual methods (jeweler's screwdriver or filed pliers) are used to reform pins, then the tool complexity is reduced, but the manufacturing precision and reliability of pin reformation deteriorates
Solution Approach 1:
The reforming tool is divided into distinct functional components: a reforming die for shaping the pin, a force applicator for controlled force application, and a spring-loaded slide block for positioning. This segmentation allows each component to be optimized for its specific function, ensuring precise pin reformation while maintaining reasonable overall complexity.
Solution Approach 2:
The spring-loaded slide block provides controlled elastic force to position the reforming die against the pin with precise pressure. By adjusting the spring characteristics, the applied force can be optimized to achieve the exact pin geometry required, ensuring manufacturing precision without requiring overly complex control systems.
2Device complexity
If manual reforming methods are used, then the device complexity is low, but the productivity deteriorates due to inability to reform multiple pins simultaneously
Solution Approach 1:
The reforming die is designed with multiple forming surfaces that can simultaneously engage and reform multiple pins in an array. The force applicator and slide block mechanism provide universal positioning and force application across all pins, allowing a single operation to reform multiple connectors, thereby significantly improving productivity.
3Ease of operation
If uncontrolled manual methods are used, then the ease of operation is improved, but the reliability of pin connections deteriorates
Solution Approach 1:
The spring-loaded slide block automatically positions the reforming die and applies consistent force during the pin reformation process. The operator simply needs to engage the tool with the pin array, and the spring mechanism self-regulates the forming pressure, eliminating the need for manual force control while ensuring reliable, consistent pin geometry and connection integrity.
4Manufacturing precision
If precise alignment mechanisms are added to the tool, then the manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
Complex multi-component alignment mechanisms are replaced with a simplified spring-loaded slide block system. The elastic spring provides both positioning and force application in a single integrated component, achieving precise pin alignment through the natural elastic deformation and contact geometry rather than through complex mechanical linkages or adjustment mechanisms.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The tool enables precise and efficient reforming of electrical connector pins to their original specifications, improving the reliability of control systems by providing a controlled and disciplined process for reforming multiple pins at once, reducing the risk of human error and increasing efficiency.
Implementation Method 1
a spring-loaded slide block that slides along an upper portion of the tool housing
Implementation Method 2
An automatic center punch is connected to an upper portion of the extension rod and is configured to transmit the preselected force to the force applicator through the extension rod
Data Source
Figure 1A
Figure 1B
Figure 2A~2B
AI summary
A tool for reforming printed circuit board backplane connector pins on a rod control system. The pin reforming tool of this invention is aligned into a card cage using existing card guides and locates itself around the backplane connector. The tool uses a uniquely designed die (that can be set up for one or multiple pin applications) that precisely engages into the connector and around the pin or pins to be reformed, with the assistance of a zig zag alignment guide matched specifically for the pin spacing. A consistent reforming force is applied via a force applicator structured to provide a force of a preselected magnitude.