Genny,
If the application, and the end user, allow it, then use the ugly and
disgusting solution of adhering the wires to the PCB. Use a removable glue.


Regards

Ofer Cohen

Quality Assurance Manager

Seabridge Ltd.


-----Original Message-----
From: Genny Gibbard [mailto:[log in to unmask]]
Sent: Friday, April 11, 2003 7:21 PM
To: [log in to unmask]
Subject: [TN] wire assembly suggestions


We have a midplane made of four interconnecting boards, involving time
consuming detailed hand assembly to put together.  Part of the interface of
this board to other parts of the system is a terminal housing of 12 wires, 7
going to one midplane board and 5 going to another.  The wires are about 2"
long, soldered on the PCB end, crimp terminals on the housing end.
Originally a 26 ga ribbon cable piece was used, but they wanted higher
current carrying capability, so went to a 22ga ribbon cable.  The ribbon
cable is so stiff, that one prototype assembler suggested going to 24ga
teflon coated stranded wire.  The first few prototypes went fine and have
exhibited no problems, but then it moved into production to finish off the
proto build and give them experience with the assembly.  Now it seems like
on every assembly they are complaining some of the wires from the terminal
housing are breaking off at the PCB.
The terminal housing sits very close to the midplane assembly, once mounted
in the chassis, and there is very little positional movement once it is
installed in the product chassis.  The wires are probably longer than we
need, but you need some length to ease the handling of assembling this.  The
wires go in sort of a J shape, straight out of the terminal housing and then
curving down or up and back to the vias on the PCB's.
They were shown how the wires were preformed and routed off the boards to
the terminal housing to limit the wiggling and strain they would go thru
once they were soldered to the boards, and they say they've done that, but
that they are still breaking.  They INSIST we find another solution.

Suggestions?

Genny Gibbard ( mailto:[log in to unmask]
<mailto:[log in to unmask]> )


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