Electronics Housing Press-In Contacts for Automated PCB Assembly
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Solution Overview
Problem
Manual assembly is required for electronic units due to manufacturing inaccuracies and the need for precise alignment of signal and power contacts with printed circuit boards, which cannot be achieved with automated processes.
Innovation Solution
Designing electronics housings with power contacts wider and longer than signal contacts, allowing them to engage with the printed circuit board first, thereby centering it accurately, enabling automated assembly by robots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual assembly is used to achieve precise alignment of contacts with printed circuit boards, then manufacturing precision is improved, but productivity decreases and labor costs increase
Solution Approach 1:
The electrical contacts are segmented into two distinct types: signal contacts with smaller width for precise electrical connections, and power contacts with larger width for automated handling. This segmentation allows each type to serve its specific function optimally while resolving the contradiction between precision and automation.
Solution Approach 2:
The power contacts act as an intermediary element that bridges the gap between automated assembly systems and the precision requirements. By using the wider power contacts as positioning references that engage first, they mediate the alignment process, enabling subsequent precise insertion of signal contacts through automated guidance.
2Productivity
If automated assembly processes are used to increase productivity, then manufacturing speed is improved, but manufacturing precision deteriorates due to inability to achieve high accuracy
Solution Approach 1:
The power contacts perform a preliminary action by engaging with their corresponding holes first during the automated insertion process. This preliminary engagement establishes the positional relationship between the printed circuit board and electronics housing, creating a reference frame that guides the subsequent insertion of signal contacts with the required precision.
Solution Approach 2:
The invention changes the dimensional parameters of the contacts by creating a size difference between power contacts and signal contacts. The power contacts have a larger width that provides sufficient tolerance for automated handling, while signal contacts maintain smaller dimensions for precise electrical connections. This parameter differentiation enables automated assembly to achieve both speed and precision.
3Power
If signal contacts have small width for low-power signals, then power transmission capability is improved, but alignment accuracy deteriorates due to difficulty in automated positioning
Solution Approach 1:
The power contacts are designed with excessive width compared to the minimum required for their function. This excessive dimension provides a larger tolerance window for automated positioning and alignment, making the assembly process more robust while the signal contacts maintain their precise, minimal dimensions for optimal electrical performance.
Data Source
AI summary
An electronics housing for accommodating and making electrical contact with a printed circuit board has at least one signal contact for connection to the printed circuit board, which is in the form of a press-in contact, and at least two power contacts for electrical connection to the printed circuit board, which are in the form of press-in contacts and have a width that is greater than the width of the at least one signal contact. The at least two power contacts are longer than the at least one signal contact for easier assembly with the printed circuit board.