Latest stamping technology yields high productivity and top quality for connector manufacturer
6 April 2005Manufacturing / Production Technology, Hardware & Services
Using the latest precise stamping technology for the highly automated production of connector contacts at its Adelberg, Germany facility, Erni is manufacturing approximately 250 000 connectors per day for its worldwide customer base. Approximately two billion contacts are produced there each year for Erni's comprehensive portfolio of connectors.
"Due in large part to our own tool-making efforts, Erni has achieved a high level of reliability in the operation of the stamping machines," stated Kurt Ziegele, technical manager at Erni. "Our optimised process and precise tools and machines allow us to run production during the night, and on the weekend, even without the plant staff, to ensure a high-level of productivity and quality."
Benchmarks
Working together with the Darmstadt Technical University's Institute for Production Engineering and Forming Machines (PtU), the 'Schulungsgesellschaft für Stanz- und Umformtechnik' (GSU) has performed benchmarking tests for stamping plants. The participating companies include Erni and several leading connector manufacturers. The tests examined the entire process chain in the stamping plants by comparing them with an ideal process. The testing parameters ranged from material handling, to tool changes, and all the way to documentation and quality assurance. Erni achieved the maximum number of points for more than half of all the parameters, and an above-average rating for all of them.
Tooling
Erni uses its in-house tool-making department and the latest, precise, stamping technology for the highly automated production of connector contacts. The company is able to maintain tolerances as low as 0,03 mm while operating at rates of 800 to 1400 strokes per minute. For example, the contact gap for the smallest connector being produced is only 0,15 mm with tolerances of ±0,03 mm, and with a cutting gap (between the die and the punching tool) of 0,003 mm. For optimised production, everything has to be perfectly tuned to match the other elements - from the precision of the stamping machine, to the tools, and on to the alignment and adjustment of the machines.
"Precise machines and an experienced and well-trained staff are indispensable," explained Ziegele.
Erni is a leading global manufacturer and worldwide supplier of a broad line of interconnects for the telecommunications, data communications, computer, industrial and medical markets
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