Ensuring reliability in safety-critical connectors

In the world of electric vehicles and aerospace engineering, reliability is paramount. Every component plays a critical role in ensuring safety, efficiency and longevity. One such component is the press-fit EloPin, a crucial element in high-performance electrical connectors. Brandauer, a renowned Birmingham-based manufacturer of precision-stamped components, has taken an innovative approach to quality control by implementing a Starrett L2 force measurement system from Optimax to test these vital connectors.

Founded over 150 years ago, Brandauer has earned an enviable reputation in precision manufacturing, even securing a prestigious Queen’s Award for international trade. The company is the only UK supplier of the EloPin press-fit, a novel technology developed by TBS Sorig. These pins must not only meet exacting dimensional tolerances but also pass rigorous pull-out force tests to ensure they remain securely in place under extreme conditions.

Measuring the insertion and extraction forces of EloPins presents a significant challenge due to their small size and the precise alignment required during the process. In response, Brandauer selected the Starrett L2 force measurement system (FMS) to ensure compliance with strict performance criteria. This automated system, designed for safety-critical applications, offers the precision and reliability necessary for such demanding environments.

To further enhance measurement accuracy, Optimax, a specialist in precision measurement solutions, designed and built a bespoke jig for the Starrett L2 FMS. The fixture allows the automatic loading and testing of various EloPin sizes, eliminating operator alignment errors and ensuring consistent, repeatable results.

The integration of the L2 Starrett system has had a profound impact on Brandauer’s production process. The machine operates continuously, testing every reel of 20,000 stamped pins, and reducing cycle times. One of the most notable advantages is its ease of use. The system is fully programmable and intuitive, allowing press shop operatives – even those with minimal inspection training – to take responsibility for quality assurance. This strategy aligns with Brandauer’s core principle of shared ownership in product quality.

Furthermore, the system’s flexibility enables Brandauer to switch seamlessly between testing the EloPin and an alternative American press-fit solution, as well as products for its Chinese clients, simply by changing the jig.

The Starrett L2 system offers manual operation and multiple software configurations, making it a versatile choice for shop-floor applications. Its simple interface ensures accessibility for operators with little or no prior experience in instrumentation. To guarantee continued accuracy, the equipment is UKAS-calibrated by Optimax, providing internationally recognised verification and reinforcing Brandauer’s commitment to rigorous quality standards.

Brandauer’s adoption of the Starrett L2 FMS underscores its dedication to technological innovation and quality assurance. By investing in state-of-the-art measurement solutions, the company is not only enhancing efficiency but also ensuring the utmost reliability of its safety-critical connectors in electric vehicles and aerospace applications.