The demand for increased reliability in automotive connector pin-end positions, which are press-fit to printed circuit boards, crucial for self-driving and driver assistance functionalities, has led to progressively tighter tolerance zones. Traditional manufacturing methods, such as cutting, bending and plastic injection, inherit limitations in achieving these tight tolerances. Connector suppliers have thus searched for innovative pin calibration methods, one of which involves correcting pins by means of permanent deformation. However, this approach exhibits challenges, including complicated processes and substantial investments due to vectorial deformation variations among different pin shapes and the necessity for spring-back control, leading to extended calibration times for individual connectors. In response to these challenges, manufacturers have explored methods utilizing the dynamic deformation properties of conductors exploiting the inertia of the components. As a viable method, it was found that vibrations with restricted amplitudes encompassing the theoretically determined pin shape could be the solution. In other words, walls around the pins vibrating up to the theoretically determined shape would force the pins to straighten.

The current project initiated as a collaboration between Aksan Kalıp and Yildiz Technical University (YTU), focuses on developing a similar pin correction method. To achieve this, one of the existing connectors in production was selected, and extensive studies were conducted. Through collaborative efforts with the university, the natural frequencies and mode shapes of the pins were determined with the finite element method by keeping the plastic body of the connector constant, and the directions in which they could be subjected to bending over their structural weaknesses were determined. It was found that position correction was achieved with the effect of limited vibrations applied at natural frequencies and harmonics. It was determined, using the finite element method, that by applying limited vibrations at the natural frequency harmonics of the pins while keeping the connector's plastic body fixed, position correction could be achieved. Geometries optimizing the vectoral vibration motion applied to the pins were subsequently identified, and a cam mechanism was designed to facilitate controlled vibration.

The first phase of the project, including all activities and results, has been presented in detail with various figures and graphs. Following the promising outcomes of the dynamic deformation-based method, it was concluded that achieving the required high vibration frequencies, as identified in the study, through the commonly used cam mechanism might not be optimal. Consequently, the design and manufacturing of an ultrasonic vibration actuator, capable of producing required vibrations with high frequencies, are also planned for the second phase of the project.The demand for increased reliability in automotive connector pin-end positions, which are press-fit to printed circuit boards, crucial for self-driving and driver assistance functionalities, has led to progressively tighter tolerance zones. Traditional manufacturing methods, such as cutting, bending and plastic injection, inherit limitations in achieving these tight tolerances. Connector suppliers have thus searched for innovative pin calibration methods, one of which involves correcting pins by means of permanent deformation. However, this approach exhibits challenges, including complicated processes and substantial investments due to vectorial deformation variations among different pin shapes and the necessity for spring-back control, leading to extended calibration times for individual connectors. In response to these challenges, manufacturers have explored methods utilizing the dynamic deformation properties of conductors exploiting the inertia of the components. As a viable method, it was found that vibrations with restricted amplitudes encompassing the theoretically determined pin shape could be the solution. In other words, walls around the pins vibrating up to the theoretically determined shape would force the pins to straighten.

The current project initiated as a collaboration between Aksan Kalıp and Yildiz Technical University (YTU), focuses on developing a similar pin correction method. To achieve this, one of the existing connectors in production was selected, and extensive studies were conducted. Through collaborative efforts with the university, the natural frequencies and mode shapes of the pins were determined with the finite element method by keeping the plastic body of the connector constant, and the directions in which they could be subjected to bending over their structural weaknesses were determined. It was found that position correction was achieved with the effect of limited vibrations applied at natural frequencies and harmonics. It was determined, using the finite element method, that by applying limited vibrations at the natural frequency harmonics of the pins while keeping the connector's plastic body fixed, position correction could be achieved. Geometries optimizing the vectoral vibration motion applied to the pins were subsequently identified, and a cam mechanism was designed to facilitate controlled vibration.