Optical measurement of press-fit pins

confovisPress fit pins

Optical 3D surface measurement for the press-fit technology

Wherever a high degree of reliability is required for electrical connections in the fields of electromobility or machine control, you will find press-fit pins (also referred to as EloPins ®). The press-fit technology uses them as components of printed circuit boards (PCBs) that are affixed by being pressed into through-plated holes. This will create a gastight and highly conductive contact between the press-fit zones and the walls of the holes. The press-fit pins have a larger diagonal than the diameter of the hole, so that a positive-locking connection is created by the deformation of pin and PCB.

Two different methods used for the optical measurement of press-fit pins

Press-fit zones need to ensure a highly conductive and mechanically stable connection with the through-plated holes in the printed circuit board. This requires measuring the press-fit pins geometrically. It is above all the edge radii, varying diameters and transitions which make high demands on the measurement technology that requires a distortion-free measurement of the component.

The Confovis measuring systems use two measurement methods that complement each other for the optical measurement of the press-fit pins in nanometer precision:

  1. focus variation
  2. confocal measurement according to the patented working principle of Structured Illumination Microscopy (SIM)

This combination will make it possible to geometrically measure both any traces of roughness and optically reflective surfaces in press-fit zones, but also larger pressing tools and pins.

Complete and distortion-free 360° measurement of press-fit pins

TOOLinspect, the optical surface measuring system from Confovis, will measure a press-fit pin in its entirety (i.e. by 360°). The system uses a motorized rotating unit to pick up the entire pin fully automatically and independently of the operator. The 3D-coordinates will subsequently be merged by the Confovis software and evaluated with the GOM® software by way of a set-actual comparison with the CAD model.

The measurement method referred to above as focus variation allows the distortion-free measurement of the press-fit pin by using its built-in high-quality optical components. But distortion-free measurements are also required on large components (such as press dies), in order to achieve an utmost degree of accuracy in the event of geometrical errors. Apart from the high quality of its optical components, Confovis also offers the opportunity to analyze roughness traceable to standards and non-proprietary roughness standards with the help of the confocal measurement method.

Apart from the press-fit pins, Confovis will also allow you to measure the relevant press dies fast, reliably and in their entirety that are used to manufacture the contacts – also with the highest possible degree of accuracy at large distances.

The Confovis measuring system TOOLinspect

The Confovis TOOLinspect system combines the patented optical measurement method (Structured Illumination Microscopy / confocal microscopy) with focus variation in one measuring system. The confocal measurement method measures different functional surfaces down to the single-digit nanometer range. This will also allow measurements on reflective, transparent and diffuse surfaces. The focus variation complements the measuring system by its excellent geometric measurement capabilities. Confovis TOOLinspect is available in different device sizes and can therefore be adapted to a wide range of measuring tasks.

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