ERNI Electronics has a manufacturing capacity of approximately 100 million connectors per year, or 4.5 billion contacts per year, in Adelberg. A comprehensive product range comprising ten different connector families with various versions requires advanced logistics and in-depth expertise, from the development and design to the manufacturing of complex and versatile contact devices, as well as the production of often quite delicate insulation devices. At the various technical seminars, visitors received information about the necessary logistics chain and the high demands placed on tooling development, stamping technology, and injection molding technology. A considerable amount of logistical work is involved in raw material supply to ensure on-time delivery and short production times. ERNI employs the Hydra Manufacturing Execution System (MES) to optimize its processes.
One of ERNI's core competencies is tool development and toolmaking. 3D CAD data from the tool development department can be directly read into existing CAM software programs in the toolmaking shop. It can then be modified or sent to downstream processors on the manufacturing machines.
The main aspect is the development of a marginal pattern for precise stamping of the contact strips. The stamping tools, which are often highly complex, are then manufactured. Fully parametric marginal patterns, along with the modular configuration of the stamping die, allow for concurrent engineering in certain cases, thus accelerating implementation time.Water cooling of the efficient stamping presses and indirect tool cooling achieve extremely small temperature variations (< 10 K), resulting in greater stamping accuracy. The generated heat is used for heating the facilities. Correction equipment is also available to ensure high device accuracy.
In order to minimize risk and focus attention on its core competencies, ERNI is turning to top-tier suppliers for contact finishing.
The construction and manufacture of the plastic parts of the insulating elements of the connectors, often complex, also requires extensive experience and in-depth knowledge of tool development, from performance specification and material selection to detailed device construction and Failure Mode and Effects Analysis (FMEA), mold tool construction, conducting a filling study to calculate the filling volume and producing the first sample of the new tool.
At the end of the manufacturing process, the contacts and insulation units are assembled to obtain the finished connector. ERNI Electronics works with numerous different connection technologies within its product range, such as Surface Mount Technology (SMT) with reflow soldering, press-fit technology, and insulator displacement connector (IDC) technology. These connection techniques were compared in another technical seminar using practical exercises.
The high quality of the final product is verified by efficient measuring and testing devices such as Automatic Optical Inspection (AOI) or a 3D X-ray tomoscope.
