ERNI Systems Technology Backplanes and Complete Systems: Design, Simulation, Production and Test www.erni.com Catalog E 074601 07/10 Edition 1 Development – From beginning to end Product concept ■ From idea to the specification sheet ■ Structuring – Connector selection – Shape factor – Communication and connection structures Equipment ■ Experienced team of developers - with over 20 years of development experience Simulation Electrical – Current distribution – Signal integrity ■ Thermal ■ Equipment ■ CST MICROWAVE STUDIO® ■ Agilent ADS® ■ Flomerics CFD® y z x ERNI component assembly Pressfit technology ■ Fully automatic pressfit assembly with automated inspection (AOI) ■ Hand press systems with PC control ■ Process control and monitoring, recording the press-in forces ■ Tools available for all connector designs ■ Suitable for large sizes (1400 mm x 600 mm) Soldering technology ■ Vapor phase soldering system ■ Convection soldering system ■ Selective soldering system Cable production ■ IDC, crimping, soldering, etc. ■ Fully automated systems for IDC ribbon cable ■ Fully automated IDC single strand ■ Fully automatic crimp center ■ Semi-automated systems for medium unit quantities: stripper crimper, IDC, etc. ■ Printing ■ Tests performed alongside production Let our experience work for you! 2 System layout ■ Signal routing and optimization ■ Component positioning ■ Power supply ■ Electrical safety Mechanical construction – electronic packaging ■ Sheet-bending structures ■ Profile-based structures ■ Composite designs Equipment ■ ORCAD® ■ Mentor Integra® ■ Mentor Expedition® ■ Bartels AutoEngineer® ■ Solid Works® Equipment ■ Solid Works® Subracks/integration ■ Housing, backplane, voltage supply, fan, cabling ■ 4 ESD assembly lines for subracks ■ Fully equipped testing stations for the safety test and system/function tests ■ Electrical and mechanical accessories for a ready-to-deliver product ■ Packaging Final inspection of backplanes ■ Fully automatic backplane test (AOI and electrical check) ■ Solutions for high contact density (> 100,000 test points, PCBs up to 1400 mm x 600 mm) ■ Connection test (up to 2 A and 4-pin measurement), insulation test (up to 1500 V) and check of passive components ■ Impedence test upon request ■ Additional tests upon request 3 ERNI Systems’ range of services From prototype to series product Prototype construction ■ Strategic partnerships with PCB manufacturers and mechanical component producers ■ Resources for prototypes Express PCB production ■ 24h assembly service Small batch production Variable production without minimum unit quantities ■ Semi-automatic assembly ■ Alternative production in North America and Europe ■ ERNI EPC3X Hydropneumatic Pressfit Center ■ Evaluation of the production efficiency ■ Production process oriented toward volume ■ ERNI EPC3X overview Process monitoring ■ Slide table ■ PCB thickness monitoring ■ Up to 30 kN press-in force ■ Supplier management ■ PCB and SMT ■ Statistical process control (SPC) ■ Adapters and tools directly from ERNI Let our experience work for you! 4 Global series production ■ Fully automatic pressfit assembly with automated inspection (AOI) ■ Hand press systems with PC control ■ Process control and monitoring, recording the press-in forces ■ Tools available for all connector designs ■ Suitable for large sizes (1400 x 600 mm) ■ UL-certified production E 258941 Logistical service around the world Semi-automatic pressing-in Fully automatic pressing-in Maximum PCB size: 1400 mm x 600 mm x 10 mm ■ ■ ■ ■ Global cable series production Supplier management ■ Cable production IDC, crimping, soldering, etc. Fully automated systems for IDC ribbon cable production Semi-automated systems for medium unit quantities Printing Tests performed alongside production ■ High degree of automation in cable production and testing ■ Tests performed alongside production – Micrographs for production approval in the cable production – Extraction force tests – IPC-A620 class 2 – Visual inspections following every operation – Adjustment gauges, check of the torques, etc. during assembly operations – UL-certified production E 332028 Logistical service around the world Flat and round cables, crimp, IDC, soldered Logistics and strategic partnership ■ ■ ■ ■ Global procurement of PCBs and components Supplier evaluation ■ ■ ■ Preferred suppliers QA agreements and audits Prototypes in shortest time Customer-specific logistics agreements High quality standardd 5 ERNI integration Subrack production Complete subrack solutions ■ Chassis with – Backplane – Power supply – Ventilation – Cooling units – Cables ■ ESD protection at assembly line ■ State-of-the-art automatic test equipment ■ ■ Test from A to Z State-of-the-art test ■ Every pitch, every connector, every BP size ■ Low set-up costs, quick test set-up ■ Test against circuit network list – Continuity – Insulation – Passive components ■ Automated optical inspection (AOI) recognizes – Twisted or incorrect components – Bent pins – Missing pins – Incompletely pressed-in connectors ■ Stores all images and test results ■ No restriction for test points ■ Coordinate measurement Let our experience work for you! 6 Comprehensive consultation for all aspects, such as – Mechanics – Security – System monitoring – Heat dissipation Customer-specific packaging Quality is our obligation We have developed and built our connectors since 1960. We design and build our own connector production equipment, our own computer-operated connector presses and our unique fully automatic press-in center with robot technology. Customer ERNI Sales & Development Support ERNI Connectors & Cable Development & Construction Pressfit technology & Integration Soldering technology & Integration Development phases 1 Concept creation 2 Pre-design simulation 3 Design 4 Prototyping 5 Design verification + approval 6 Pre-production series 7 Local series production Services and products ■ We install components from every manufacturer ■ Cost reduction when using ERNI products ■ No tool costs if ERNI connectors are used ■ Customer-specific connector development and production ■ 24-hour service for express production and delivery ■ No order is too small or too large Development and production ■ We combine your ideas, ERNI products and the development experience of our engineers in order to have your product created ■ ERNI can help you during every stage of your system development, from the design to the series production ■ Backplane revision for cost reduction and to increase system performance ■ Flexibility to relocate production internationally between similar production facilities ■ Low one-off costs for test set-ups ■ We build our own connectors, tools and presses, whereby our customers are offered a high level of experience ■ Highest degree of automation of all system production providers Quality and reliability ■ Our high quality standard ensures that ERNI production is good production ■ State-of-the-art test technologies ■ Maximum of 3 day test set-up time thanks to the flexibility of our testing options ■ ISO 9000 certified ■ UL approved ■ TS 16949 in planning ■ All machine operators are IPC-A610 trained ■ IPC-A610 class 2 7 Whatever you need: In line with your design. In line with your schedule. Whatever your unit quantity. ERNI Systems is an ideal solution for a “ready-for-operation” production service: We produce customer-specific backplanes and complete system platforms in small and large unit quantities. If you see our EPC III pick-and-place pressfit center in operation, then you know how much ERNI know-how the production contains. From tape-and-reel packaging to the shape and color of component housing; from SMT, THR or pressfit connections to specially developed tools: Each individual process is optimized for automated processing. The measurement of the position of the contacts is performed by camera systems before pressing-in with a defined force. The PCBs are assembled, soldered and then tested as per exact specifications. We apply all the technical advances of system technology for our customers. ERNI Electronics GmbH The Technology Center Connectors Development + Production Backplanes and complete systems Development + Production SMT & THT Soldering Development +Production Cable assembly Development + Production ERNI Electronics GmbH Seestrasse 9 73099 Adelberg, Germany Tel.: +49 7166 / 50-0 Fax: +49 7166 / 50-282 [email protected] Catalog E 074601 ERNI Electronics, Inc. 2201 Westwood Ave Richmond, VA 23230 USA Tel.: +1 804-228-4100 Fax: +1 804-228-4099 [email protected] 07/10 ERNI Asia Holding Pte Ltd Blk 4008 Ang Mo Kio Avenue 10 #04-01/02 Techplace I Singapore 569625 Tel.: +65 6 555 5885 Fax: +65 6 555 5995 [email protected] Edition 1