How are industrial connectors made in a factory?

What is an industrial connector? Simply put, it is a kind of electrical signal exchanger, the signal through the connector in two different signal media to realize the transmission, it can be compared to the image of electronic circuits in the communication of the "bridge". It plays a large role, a wide range of applications, in machinery and equipment, chemical smelting, electronic information and other aspects of the use of the more common. Now on the market for industrial connectors, functionality and previous compared to a lot more. There are waterproof, anti-salt spray, high temperature resistant, etc. Despite the wide variety of connectors, but their basic function is the same, is to achieve the exchange of signal transmission. So the manufacturing process is still basically the same, roughly divided into four stages: stamping, plating, injection molding, assembly.

Stamping pins for stamped connectors. The raw material used to make pins is copper metal, which has good electrical conductivity. Using a large high-speed stamping machine, large rolls of metal tape can be stamped into a large number of finished products with different specifications in an instant. Machine stamping, too much or too little pressure will affect the performance of molded products, stamping before the need to do a good job of precision debugging is very important. Electroplating stamping after molding pins, the next need to do plating measures, electroplating on the surface of the special metal coating to enhance the conductive properties of the pins. Before plating, some unqualified pins such as twisted, deformed, should be removed from the product, rework and continue production. The pins go through a number of processes in the electroplating equipment and are finally dried. Electroplating and stamping process is the same, in the electroplating process there will be unqualified substandard products appear. For example: tiny scratches, pinholes and so on. These quality defects, the naked eye alone is difficult to find, the manufacturer uses a set of visual inspection system, which can detect quality defects and remove these from the product, effectively ensuring the quality of the pin plating. The base of the injection-molded connector is plastic, manufactured by injection molding methods. The process is relatively simple: first melt the plastic at high temperatures, then poured into the mold cavity filled with models, and finally to be cooled to molding. Injection molding process, if the operation is not appropriate, it is easy to produce many quality problems, the more typical quality problems are so many kinds: 1. melted plastic is not completely filled with mold cavity, molded products will appear "missing pieces " phenomenon, 2. melting liquid overflow, easy to jack is filled with plastic or partially blocked, affecting the subsequent assembly work. After molding, you need to check whether the product is qualified. If you use manual labor to check one by one, it is time-consuming and inefficient. Now there are specialized testing equipment - backlight tester, through the ultraviolet light penetrates the product, quickly identify the base leakage and jack clogging problems of the product. Assembly of industrial connectors manufacturing the last process is the finished product assembly. The above plated pins and plastic chassis are combined to complete the finished product. There are two ways of assembly, one is a separate pair of plugs, there is a combination of plugs. Individual pairs of insertion: the combination of each time to insert a pin, until the plastic base is inserted into the full position. The advantage is that the precision of pin insertion is relatively high, but it is time-consuming. Combination of pairs of pins: multiple pins are arranged in a regular manner, one-time simultaneous connection and insertion with the box base. The advantage is that the assembly speed is faster, but the precision is not as good as the former. This different assembly methods have their own advantages and disadvantages, manufacturers can choose according to user requirements. After the assembly is completed, we have to test the machine to see if its external dimensions have exceeded the design tolerance range, pin assembly is used firmly, whether the precision has no effect. There are many ways to test, the more common is to use the "actual position" method of testing.

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