CASE STUDY SIX - BESPOKE 128 PIN BACKPLANE CONNECTOR
We were approached by the customer with a request for urgent help. They had been using a bespoke 128 pin backplane connector for many years when ‘out of the blue’ their supplier told them that they could no longer make it and that supply would stop with in 20 weeks!
Our brief was to mfr an equivalent connector that would have to retro fit all existing equipment and more importantly to withstand their production methods and parameters and give them a product they can rely on for many years to come. All of this had to meet their stringent budget costs.
On looking at the specifications supplied by the customer we realised that the connector had many inherent design issues that had caused manufacturing and mating problems in the past due to the stability and alignment of the 3 rows of pins.
Using 3D CAD/CAM design our design engineers re- modelled the moulded body of the connector to improve manufacturing yield and re-design the way the brass pins were held in place and added more structural support.
These models were then sent to the customer for initial approval which they were happy to sign off. This then enabled us to move forward with the initial tooling. Great care and attention is required at this stage to ensure that once the tooling is made we minimise the need to adjust the design/tooling and thereby vastly increasing the time it takes to start production runs.
We were able to complete the tooling within a 6 week period with 1st off sample being available to the customer 2 weeks after that. These were put through rigorous tests to ensure Fit, Form and Function and to ensure they with stood production line tests. All tests passed with flying colours and the customer quickly signed them off for production.
Due to the improved design features and quick response times, we were then able to start supplying full production volumes within the very tight time frame imposed on us and therefore preventing any production line stops at the customer, who in turn experienced a seamless transition to the new connector. We are now supplying this product in 10s of thousands per year and not only do we now supply the customer with a vastly improved product, we are able to supply at a lower cost and save them money.
See other Case Studies:
Case Study One - Cable Assembly
Case Study Two - Bespoke Connector System
Case Study Three - CF (Compact Flash) Card Kit
Case Study Four - Bespoke Docking Connector System
Case Study Five - Terminal Block
Case Study Seven - PIR Motion Module Overmoulding
Case Study Eight -
Bespoke Medical Cable
