Circuit Board Assembly

Optimizing Circuit Board Assembly with Compliant Pin Technology

Challenge

Solution

To overcome these challenges, the manufacturer explored an alternative assembly process using compliant pin technology. Instead of soldering, connectors would be press-fitted into circuit boards using specially designed pins. These pins, being radially flexible, ensured a mechanically and electrically stable connection without the need for a soldering operation. This transition promised to improve the process and reduce energy consumption.

However, press-fit assembly introduced its own set of complications. Potential issues included:

• Bent pins misaligning with the board
• Mismatched or incorrect connectors being installed
• Obstructed holes due to manufacturing imperfections
• Machine misalignment causing damage to the components

Implementation: Intelligent Press-Fit Assembly

To address these risks, the manufacturer integrated a Promess Electro-Mechanical Assembly Press (EMAP) equipped with advanced sensors and proprietary software. The key to success was Promess’ Digital Signal Conditioner (DSC), which allowed for precise monitoring of the initial engagement between the connector and the circuit board.

• High-Precision Force Measurement: The DSC’s built-in linearization algorithm ensured accurate force detection, even at the lowest end of its measurement range. This enabled early detection of issues before any damage occurred.
• Closed-Loop Positioning Control: If the system detected an anomaly, it automatically halted the press cycle, preventing costly scrap and rework.
• Data-Driven Quality Assurance: The system captured force and position data for each assembly, ensuring traceability and compliance with stringent quality standards.

Results & Benefits

By implementing Promess’ intelligent press-fit solution, the manufacturer achieved:

• Significant Reduction in Scrap: The ability to detect misalignments and defects before full engagement drastically reduced costly rework and material waste.
• Energy Efficiency: Unlike traditional soldering irons that consume energy continuously, the electro-mechanical press only draws power during operation.
• Process Flexibility: The fully programmable system allowed the same press to handle a variety of connector and board configurations with simple fixture changes, supporting lean manufacturing principles.
• Enhanced Reliability: Automated precision ensured consistent, high-quality assembly, improving product reliability and reducing field failures.

Through the adoption of Promess’ Electro-Mechanical Assembly Press and compliant pin technology, the circuit board manufacturer successfully transitioned to a more efficient and cost-effective assembly process. This case study highlights how advanced automation and intelligent sensing can revolutionize traditional manufacturing challenges, leading to higher productivity, reduced waste, and greater sustainability in electronics production.