I would request any data the customer has validating their statement that damage is directly related to lead forming and lead trimming. I think you would need to know what the failure mode is before you could assign root cause. It sounds like there was no failure mode analysis completed at your facility to assign root cause, backing up Bev's initial statement this is most likely a knee jerk reaction by the customer.
From: TechNet [mailto:[log in to unmask]] On Behalf Of Steve Gregory
Sent: Thursday, July 28, 2016 10:49 AM
To: [log in to unmask]
Subject: Re: Prepping TO-5 can style Relay...
To be honest, I don't know for sure, I'm assuming they do. I'm just trying to learn if anybody else has experienced this problem to see how widespread this might be...
On Thu, Jul 28, 2016 at 9:44 AM, Bev Christian <[log in to unmask]>
> Do they have PROOF that bending the leads cause damage?
> -----Original Message-----
> From: TechNet [mailto:[log in to unmask]] On Behalf Of Steve Gregory
> Sent: Thursday, July 28, 2016 11:12 AM
> To: [log in to unmask]
> Subject: [TN] Prepping TO-5 can style Relay...
> Hi All,
> We're building a board for a customer that uses a 8-lead TO-5 style relay.
> The footprint on the board requires that the leads are spread out to a
> larger diameter circle than what diameter is when they come out of the
> body at the bottom of the relay. Here's the information for one of the
> relays, there are three others that are the same style:
> So we have a Simonds CLP274 lead processor with a die that matches the
> footprint on the PCB:
> We insert the part which spreads the leads out, then step on the pedal
> and a guillotine style blade shears the leads off. I've used the prep
> unit many, many time before at previous employers without issues. The
> customer is saying that prepping the leads in this unit is damaging
> the relay. So now we are to pot the leads before prepping them with a
> 2-part epoxy using a tooling fixture as a mold for the epoxy, and the
> potted relay looks like
> Has anybody ever heard of this Simonds unit damaging relays like this?
> Has anybody had to add potting to a relay like this? I can understand
> wanting to keep the leads coming straight out of the bottom of the
> body before making the bend to match the footprint on the board, but I
> think I can use a Bivar permanent spacer and slip it over the lead and
> accomplish the same thing. Something like this:
> Or even a nylon washer that matches the diameter of the lead pattern
> (.200") coming out of the bottom of the relay. Potting this relay is
> going to be very time consuming and there's going to be a risk of
> getting the epoxy on the leads that will ruin the solderability of the
> part. I'm just trying to understand if it is truly the Simonds prep
> unit causing the damage, and if this really is, and easier way other
> than potting them to accomplish the same thing.
> Thanks all!
> Steve Gregory
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