There are many solutions that we have available for different sectors and applications, both catalog and customized. In this case study we will talk about how we found the appropriate solution for a technology that deals with wiring tests, on dedicated benches, within the automotive industry.
This is the situation in which our contribution was requested: the customer works in the field of testing of wiring for the automotive sector and creates dedicated test benches, with a series of counterparts to which all the connectors to be tested are connected.
The realization of the test bench is strictly bound to the shapes and dimensions of the connectors connected to the wiring and is therefore extremely varied.
Here are the steps that led to finding the ideal solution for this application:
- the primary necessity was to vary the family of probes used, passing from the standard ICT (receptacle plus pressure inserted probe) to the screws in probes (threaded receptacle plus threaded probe);
- the new configuration that we have studied aligns with the standard used in this field of reference, which needs the use of this family of probes for technical and functional reasons;
- the criticality was in not being able to use a product in the catalog, because of the multiple configurations used to test the different connectors;
- the first phase involved the development of 3D models that are fundamental for the customer to implement them in the projects of the counterparties;
- once 3D were approved, it has been created a probe base with the main features needed, which will be configured by the customer according to the tip style and diameters required head, but maintaining the main common features;
- we have managed in this way to provide a custom version easily configurable, which for series production contains common achievements that allow to reduce the costs of the probe itself;
- we then designed and developed a dedicated tool for inserting probes into their respective receptacles, which could be used for most of the required probes.
The analysis of the design and the dimensional constraints, together with the 3D design, allowed us to realize this product line obtaining two results: switching of the probes families and maintaining a competitive and sustainable price.