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Compare this to (b), where pin shavbath stagnation and exhaustion a zone of poor elec- ing is evident but the pin is in intimate contact trolyte circulation within the high-aspect-ratio barrel with the PTH barrel (Scanning electron microThis condition may also lead to poor contact of the scope (SEM) micrographs courtesy of A press-fit pin against the PTH barrel wall and contact Alexander, Jabil Circuits, Penang, Malaysia) reliability issues The opposite can be detrimental also, where the PWB vendor strives to attain the proper plating thickness within the PTH barrel, but plates too much material at the barrel openings and on annular rings 4963 Slivers The Pb of Sn-Pb solder-coated barrels is known to reduce the force required for pressfit connector insertion and seating.

Although Sn-Pb coating is one of the best surface finishes for pressing, if it is thick, then the pressfit connector pin may skive a thin sliver of solder and push it out the secondary side of the PWB (see Fig 498) Very often these slivers.

remain attached to the pin or the PWB, or they become jammed between the pin and barrel. The sliver may break free of its source and cause an electrical short locally or elsewhere in the system.

Several types of mechanical presses are used for applying press-fit connectors to PWBs. The lever-activated arbor press is the most primitive but suffices for simple, low-lead-count, coarsepitch connectors. One step up is the pneumatically driven press. Although it is easier to operate than the lever-activated arbor press, it does little for process control or assembly repeatability. Higher on the evolutionary scale is the pneumatic/hydraulic combination (the so-called airover-oil press), which offers a somewhat more controllable process. High-precision pressing cycles are mandated by the latest press-pin connectors with their delicate, molded body features, fragile electrical shielding, and fine pin pitch, so it is advisable to use a machine that is computercontrolled.Aside from force and speed precision for process reproducibility, press cycle data can be stored along with process recipes for ram force, speed of compression, and component location if equipped with programmable axes. Data logging is critical for statistical process control and is useful for press cycle root-cause defect analysis or machine troubleshooting. The state-of-the-art connector press is electromechanically actuated, relying on a motordriven coarse-pitch lead screw with tachometer speed control, z-axis positional encoders, and load cell feedback for an accurate pressing cycle (see Fig. 49.9).

Some commercially available machines are automated even to the point that they are able to shuttle boards into the press, pick and place connectors, select a connector-appropriate pressing tool and supporting tool anvil, rotate the tools to the proper orientation, and press multiple connectors sequentially on a single board or multiple nested boards. There are several ways to control the press-fit process. Methods and merits of each are discussed in the remainder of this chapter, but first a more detailed review of the mechanics of the press-fit process is in order.

Press tool and support plate are fabricated to match connector requirements and PCA layout. The PCA is placed on the press-fit tooling fixture support plate. The operator manually places the connector into the appropriate plated through-holes in the PWB. The ram and tool are aligned to the connector to be pressed. When press-fit connector leads are forced into PWB plated through-holes during a pressing cycle, there is a characteristic fingerprint of force versus vertical distance traveled for each connector and PWB type.The various events and slopes that comprise the fingerprint are shown in Fig. 49.10. As pressing progresses, connector leads are forced into the plated through-holes and the compliant section of its pins deform elastically, then plastically. Continued resistance is encountered due to the friction of the collapsed pins sliding along the PTH barrel walls. Another inflection in the plot occurs where the connector fully seats against the PWB. Further force affects little or no change in distance and the press cycle ceases. Were the cycle to continue, damage to the PWB would result.

FIGURE 49.10 Force versus distance plot of a press-fit cycle. Inflection points and regions are as follows: (a) initial force is applied to the press-fit connector; (b) the compliant section of the pin collapses; (c) the pin collapse is complete; (d) the pin slides along PTH barrel wall, creating friction; (e) the connector is fully seated; (f) continued pressing makes little change in press distance. The pressing cycle is complete.

For best results, a method that allows real-time measurement and control of the pressing process is preferred and is available on today s commercial presses. There are four commonly used pressing routines, but only three take advantage of force-sensing, distance-sensing, or real-time feedback control of the connector press. Connector complexity and equipment availability dictate press-fit assembly methodology.