Testing of Plug Contacts

Diehl Metall is one of the largest producers of semi-finished parts, forgings, and rolled products in the world. Another area in which the company is active includes the manufacture of stamped parts and their galvanized coating. A significant portion of these parts is used as plug contacts on printed circuit boards (PCB) in the automotive industry. As an important quality control measure of the connection of plug contacts and boards, Diehl Metal Applications GmbH opted for a testing system from ZwickRoell.
Single Pin Insertion
Electromechanical servo testing actuator
In contrast to soldering technology, press-fit technology established itself as the connection technology for contacts and circuit boards in the automotive industry long ago. For press-fit technology, there are two different speeds–slow insertion and fast insertion. In the latter case, often referred to as “SPI – Single Pin Insertion”, the contacts are inserted into the through connection of the PCB at a speed of > 300 mm/s. The high speed, along with the demands on the flexibility of both connection partners in the placement process place special requirements on the connection. The ability to evaluate the quality and standard of the connection of the press-fit contact and PCB via the documentation of the force curve during the entire insertion process is essential. Diehl Metal Applications GmbH successfully uses a testing system from ZwickRoell for this type of quality assurance and for product optimization. An electromechanical servo testing actuator is mounted in a compact test frame. The press-fit force and the complete press-fit curve are displayed with a Piezo force sensor and a sampling rate of 2 MHz during testing. The evaluation of the test results was performed with a special software primarily used for dynamic testing and measuring systems such as high-speed testing machines (HTM) from the company ZwickRoell.