Design, engineering, technology

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A set of tooling for the production of an electrotechnical component
( Design, manufacturing support, and commissioning )

The component consists of a functional part (gold-colored, shown schematically) that is enclosed in a housing (red) and has two terminals, each with two contacts

Note. If we see that a component has 4 pins, it may mean one of two things: either all 4 pins are independent, or the component actually has two pins that are duplicated.

Duplicated pins (as in this case) are used for several reasons:

– For mechanical stability (so the component holds better on the PCB);

– To increase conductivity (if the component carries a significant current, duplicating the pins reduces resistance);

– For easier routing and assembly (sometimes PCB layout is simpler when there are two leads for the same line)

A single component is cut out from a multi-blank containing 14 such pieces

To produce this multi-blank, a progressive die first forms a grid from a metal strip (for scale, I placed a match next to it)

Then, the functional parts are soldered onto this grid

After that, two such grids are placed into a compression mold, where the housing of the component is formed from a rigid thermosetting polymer based on epoxy resin cured with novolac resin

Compression mold 👉

A set of pullers is used for disassembly, carried out as follows 👇

Using pullers A and B, the punch holder (1) is removed

Using pullers A and C, the runner plate (2) is removed

Using puller D, the lower half of the mold (3) is separated from the casting with the runner and the upper half of the mold

After manually removing the runner (4), puller E is used to separate the upper half of the mold (5) from the multi-blanks mentioned earlier

Afterward, a single component is cut out from the multi-blank in a progressive die, and its contacts are bent. This die already belonged to the client (as this operation is standard, and one die can produce various components that are comparable in size but not identical) and was not the subject of design or manufacturing

Example of the component on board

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