ExaMAX2 VH&VR&MEZZ2 high-speed backplane assembly and inspection line of a certain company

High-speed backplane connectors are critical interconnect components in data centers and communications equipment. As device transmission rates increase and connection density increases, connector assembly not only requires higher precision, but also requires the formation of a stable closed loop in inspection, packaging and traceability. The ExaMAX2 VH&VR&MEZZ2 project caters to the high-speed backplane needs of data centers and communication equipment. FCI provides high-speed backplane connectors, and MIJOINT provides automation solutions and equipment.

Project background

ExaMAX2 VH&VR&MEZZ2 connectors are used in communication equipment to connect backplanes and sub-boards to achieve high-speed data transmission and ensure signal integrity. This type of connector has a large number of PINs, compact structure, and high assembly difficulty. It places high requirements on the assembly position, pin stability, and detection accuracy of components such as Housing, T-TOP, and Tail Organizer.

This project requires the completion of the assembly, inspection and packaging of the Housing, T-TOP and Tail Organizer, and the alignment, GAP and height dimensions through AOI and 3D inspection. The project is not only a case of automated connector assembly, but also a concentrated display of high-speed backplane connector testing and packaging capabilities.

Automation Solution

MIJOINT Intelligent built an automated complete line for the ExaMAX2 project, including an electrical testing machine, Housing Tube loading machine, T-TOP pin insertion machine, Tail Organizer assembly machine, size inspection machine and Tube tube packaging machine. The entire line revolves around automatic loading, pin insertion, assembly, testing and packaging, reducing manual participation and improving assembly consistency.

In the T-TOP pin insertion process, the project uses a combination of a full cam mechanism and mold cutting to achieve high-speed insertion of multiple PINs in sequence. The single PIN insertion speed of PPT marking equipment is CT < 0.6s, which not only meets the rhythm requirements, but also avoids T-TOP deformation, Housing abrasions and PIN foot damage.

The Tail Organizer assembly process uses flexible vibration plates, visual guidance and robotic gripping. Since the Tail Organizer's automatic loading and grabbing is difficult and 598 fisheye needles need to be inserted, the equipment achieves precise positioning and insertion through linear motor displacement and high-precision guide blocks. In the inspection process, a 6500W pixel large-field camera is used, combined with the underlying algorithm of Cognex software, to detect needle position, GAP and height dimensions.

Process Difficulties

The first difficulty in this project is the multi-PIN high-speed pins. T-TOP is a three-in-one assembly that requires cutting the material bridge and completing the assembly. During the sequential insertion of multiple PINs, insertion damage, deformation, and positional deviation are prone to occur. MIJOINT assembles an integrated module through a cam mold to improve pin insertion speed and consistency.

The second most difficult point is loading and assembling the Tail Organizer. It is difficult to automatically load and grab this part, and there are a large number of fisheye needles inserted, which requires high positioning accuracy. Flexible vibration plates, visual guidance and robot gripping can improve the adaptability of loading, while linear motors and high-precision guide blocks are used to ensure the insertion position.

The third difficulty is high-precision visual inspection. It is necessary to detect the position of 598 needles, with an error requirement of < ±0.03, and process capability goals such as CMA ≥ 1.67 and CPK ≥ 1.33 are proposed. The project uses a 6500W pixel camera with a field of view size of 56 × 42mm and a camera resolution of 9344 × 7000pixels, which reflects the project’s requirements for detection accuracy and algorithm stability.

Customer value

The ExaMAX2 automatic assembly and inspection line integrates high-speed pin insertion, flexible feeding, visual guidance, 2D/3D inspection and automatic packaging into one production line, helping customers reduce the difficulty of manual assembly and improve the consistency and process controllability of high-speed backplane connector manufacturing.

For data centers and 5G communication equipment supply chains, connector production must not only meet single-point assembly accuracy, but also meet process capabilities and inspection closed loops in mass production. MIJOINT Intelligence demonstrated its comprehensive capabilities in connector precision assembly and high-precision inspection in this project, and also provided a reusable solution for similar high-speed backplane connector projects.