How much current are you trying to get in and out of these things? Which is the DUT, the wire harness or the PCB? Guess it's the PCB if current is a concern, since you wouldn't need a ton of current for most harness testing purposes?
Conventional solution to pogo pin pressure is to use a mechanical clamp system, like a cam-like style of thing that has high mechanical advantage to make opening and closing easy. Potentially many other solutions--maybe even just some big heavy alligator clips that can clip onto the terminal?
How much current are you trying to get in and out of these things? Which is the DUT, the wire harness or the PCB? Guess it's the PCB if current is a concern, since you wouldn't need a ton of current for most harness testing purposes?
Conventional solution to pogo pin pressure is to use a mechanical clamp system, like a cam-like style of thing that has high mechanical advantage to make opening and closing easy. Potentially many other solutions--maybe even just some big heavy alligator clips that can clip onto the terminal?
DUT is PCBA with the press fit terminals on it. To test it I have to connect the motors to the PCB with thick ring terminal wires.
The power also comes in on other terminals as well. So 5 terminals total (motors have a common).
How much current are you trying to get in and out of these things? Which is the DUT, the wire harness or the PCB? Guess it's the PCB if current is a concern, since you wouldn't need a ton of current for most harness testing purposes?
Conventional solution to pogo pin pressure is to use a mechanical clamp system, like a cam-like style of thing that has high mechanical advantage to make opening and closing easy. Potentially many other solutions--maybe even just some big heavy alligator clips that can clip onto the terminal?
DUT is PCBA with the press fit terminals on it. To test it I have to connect the motors to the PCB with thick ring terminal wires.
The power also comes in on other terminals as well. So 5 terminals total (motors have a common).
if it is just for a test fixture can't you just make a "hat" that clamps on top pushing on top each of the ring terminals
Maybe add a spacer to the lugs on the test setup the nut only needs a couple of turns?
Also, using threaded spacers, maybe 10mm long, instead of nuts makes them much easier to start and hand-tighten
How much current are you trying to get in and out of these things? Which is the DUT, the wire harness or the PCB? Guess it's the PCB if current is a concern, since you wouldn't need a ton of current for most harness testing purposes?
Conventional solution to pogo pin pressure is to use a mechanical clamp system, like a cam-like style of thing that has high mechanical advantage to make opening and closing easy. Potentially many other solutions--maybe even just some big heavy alligator clips that can clip onto the terminal?
DUT is PCBA with the press fit terminals on it. To test it I have to connect the motors to the PCB with thick ring terminal wires.
The power also comes in on other terminals as well. So 5 terminals total (motors have a common).
if it is just for a test fixture can't you just make a "hat" that clamps on top pushing on top each of the ring terminals
Yeah, that is the kind of thing i want. Do you know if anyone makes something like that ready to go?
I also wonder if you could make something like croc/alligator clips with a cylindrical profile inside the jaws. Maybe copper braid.
Or maybe cut a brass M6 nut in half and solder the halves inside the jaws of croc-clips
There is also the risk that the current will heat the springs up and they will lose their springiness.
But given that the 180A is only for a short time, might be able to get away with using less of them
There is also the risk that the current will heat the springs up and they will lose their springiness.
But given that the 180A is only for a short time, might be able to get away with using less of them
Might be worth including a couple of extra pogo pins for each terminal so you can monitor contact resistance. Two additional pins that are isolated from the other pins but contact the same copper area would allow you to take a four-wire measurement of the total pin+contact resistance for your power handling pins. The measurement pins don't even need to be the fancy high-current ones. You could take measurements periodically to monitor if/how the contact resistance degrades over time, or make it part of every test cycle. The latter would be a good way to verify that the board is properly loaded into the fixture before starting the test and trying to get 180A through only half of the pogo pins. In a more pedestrian test fixture you might just use some detector pins set at a lower height than the rest of the test pins for that purpose.
Can't you test the PCB before the press fit terminals are installed? You have a nice number of through hole connections where those pogo pins would make ideal contact.
Can't you test the PCB before the press fit terminals are installed? You have a nice number of through hole connections where those pogo pins would make ideal contact.
I could do, it's an option.
What about a female “banana” jack (I use the term loosely, because these jacks have the springy lantern inside the jack, intended for use with solid pins) like the ones from Stäubli? They come in numerous diameters, including 6mm, which you could push onto the M6 stud.