ERNI Technology Day

ERNI Electronics presented efficient manufacturing processes for innovative connector products at the company’s in-house exhibition

Adelberg, November 17, 2009 – ERNI Electronics presented innovative and sophisticated automated manufacturing processes for modern connectors at its “Technology Day” in Adelberg. Interested visiting experts and customers took the opportunity to have a detailed look at the company’s comprehensive know-how in the areas of tool development, stamping, injection molding, and backplane manufacturing and connection techniques as part of a tour of the factory and during the course of a number of workshops. ERNI Electronics has manufacturing capacity of approximately 100 million connectors/annum or 4.5 billion contacts per annum in Adelberg. An extensive product portfolio consisting of ten different connector families with various variants requires sophisticated logistics and comprehensive expertise, starting with development and construction to the manufacture of complex and versatile contact parts and the production of isolation parts that are often quite delicate. In the various workshops the visitors were informed about the logistics chain that is required, and the high demands that are made in the tool development, stamping technology and injection molding technology areas. A considerable amount of logistics work when the raw material is being procured in order to ensure that supply deadlines are met and throughput times are short. ERNI uses the Hydra Manufacturing Execution System (MES) to optimise its processes. One of ERNI’s core competences is tool development and tool manufacturing. The 3D CAD data from the tool development department can be directly read into the existing CAM-software programs in the tool making shop. They can then be modified and sent to the post processors of the manufacturing machines. The main focus is on the development of a fringe pattern for precise stamping the contact strips. This is followed by the manufacture of the stamping tools, which are often highly complex. The fully parametric designed fringe patterns together with the modular configuration of the stamping die allow in certain cases a simultaneous engineering, so that the implementation time can be speeded up. Water cooling of the efficient stamping presses and indirect tool cooling can achieve extremely small temperature variations (< 10 K), which results in higher stamping accuracy. The waste heat is used to heat the facility. The high precision of the parts is also supported by straightening equipment. In order to minimize the risk and allowing focusing on its core competences, ERNI is using high performing suppliers for the contact finish. The construction and manufacture of the plastic parts for the insulation bodies of the connectors, which are often complex, requires also in-depth know-how and knowledge of the fine art of tool development – from the performance specification and selection of the material to the detailed construction of the parts and FMEA (Failure Mode and Effects Analysis), to the construction of the molding tool, carrying out a filling study for assessments of the filling volume and producing the first sample of the new tool. At the end of the manufacturing process, the contacts and the insulation units are assembled to produce the finished connector. ERNI Electronics supports many different connection technologies with its product portfolio, such as SMT (Surface Mount Technology) with reflow soldering, press-fit technology and insulation displacement connector (IDC) technology. These connection techniques were compared in another workshop and supported by practical exercises. The high quality of the final product is checked using efficient measuring and testing devices such as AOI (Automatic Optical Inspection) or a 3D X-ray tomoscope.

ERNI Electronics GmbH ERNI Electronics GmbH was founded in 1956 and their place of business is Adelberg / Germany. They are a part of the company group ERNI International AG. ERNI is developing and producing a big variety of connectors, backplanes and complete systems, solder assemblies and cable systems. ERNI is a global operating company with their own branches in Europe, North America and Asia. Further information is available at www.erni.com