Pogo Pin, Our Tailored Connectivity Technology, Designed Specifically for Your Business Needs. Unveiling Our High-Performance Pogo Pin Solutions, Boosting Connectivity Reliability, Driving Business Growth！

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We know, for a pogo pin, the best working condition about force direction. Is to completely follow the working direction of the plunger. Which will avoid the friction between the plunger and the inner wall of the barrel. Because the friction will greatly drop the life cycle of the pogo pins.

Then, how to solve the issue of lateral force?

Problem Statements from our customer:

• Our customer ordered some Pogo pins samples at the beginning of this year. However, our customers hoped the pogo pin samples could also meet new requests. With 45° lateral force in another new project.
  Root Cause for Pogo Pin Problem:
• For the pogo pins, if the angle is less than 10° between UUT and the pogo pin, it is acceptable. if the angle is 15°, the life cycle of the pogo pins will be less than 2000. Which is one-fifth of the standard life-cycle 10,000 times.
• The root cause is the friction， wear & tear between the plunger and the inner wall of the barrel.

Solution for Pogo Pin Problem:

How to solve the angle issue? which brings us an obvious lateral force. And reduce the life cycle, even, damaging the pogo pin.

1. Pin Structure Optimization:

• Ball Head Design: Design the pinhead of the pogo pin as an embedded ball head to eliminate lateral forces through ball rolling.
• Increased Pin Diameter: Increase the pogo pin diameter during design to provide greater resistance to bending, thereby withstanding larger lateral forces without deformation.
• Multi-Point Contact Design: Disperse the effects of lateral forces by designing multiple contact points, enhancing both connection stability and electrical performance.

2. Precise Pin Socket Design:

• Guiding Features: Incorporate guiding grooves or pillars in the pogo pin socket design to ensure vertical alignment during insertion and extraction. Reducing lateral forces caused by misalignment.
• Shock Absorption Design: Surround the pogo pin socket with cushioning materials or elastic components to absorb impact and pressure from accidental lateral forces.

3. Material Selection and Treatment:

• High-Strength Materials: Choose high-strength, wear-resistant metal materials, such as hardened steel or high-strength copper alloys, to enhance the pin’s resistance to lateral forces.
• Surface Treatment: Implement suitable surface finishes, such as gold plating, palladium plating, platinum plating, or silver plating, for improved efficiency. It is to improve conductivity, as well as enhance material durability and corrosion resistance.

4. Installation Design Optimization:

• Installation Accuracy: Ensure extremely high precision in the installation positions of both the pogo pins and corresponding connectors. It is to avoid additional lateral forces due to installation errors.
• Mechanical Fixation Methods: Employ more robust mechanical fixation methods, such as screws or welding, to ensure pin stability under lateral forces.

5. Simulation and Testing:

• Mechanical Simulation: Conduct mechanical simulations during the design phase to analyze the behavior and stress distribution of pogo pins under lateral forces. Optimizing the design accordingly.
• Prototype Testing: Fabricate prototypes and conduct practical tests, including lateral force and durability tests. To ensure the design meets various requirements in real-world applications.

Result:

Ball Head Design: We’ve opted for a ball shape for the pogo pin head, which naturally mitigates the impact of lateral forces on connection stability. The ball head allows for slight rotations and adjustments on the contact surface. This enables the pogo pin to accommodate lateral movements during insertion or connection, reducing damage from friction or misalignment.

Enhanced Elasticity: By using the high-quality spring, we ensure the pogo pin maintains good contact pressure even when subjected to lateral forces. The spring’s elasticity enables the ball head to stay stable at the contact points. While absorbing some of the impact and pressure caused by lateral forces.

Precision Manufacturing and Assembly: Our high-precision manufacturing processes guarantee the exact size and shape of the ball head pogo pin. Ensuring proper fit within the receptacle and minimizing additional lateral pressure due to misalignment.

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That is, we need to keep the strong magnetic force without changing N52. And reduce the interference of magnetic force to components on the PCB board.

Problem Statement from customer:

• The magnetic force of the Pogo pin is enough. But, during the tests, we had some troubles, caused by the interferences of the magnet on our board.
  We need electrical insulation on the surfaces of the runway magnet.
• Just for info, is there the possibility of shielding also the magnetic field with foils or other systems? To avoid also magnetic interferences with components on the boards.

Preliminary requirements from the customer:

• For the surface of the magnet! We work out how to paint it and protect the surface with electrical insulation.
• The proposed max thickness is 0.1mm.
• For the green and blue areas, don’t need to insulate the surface. But insulation is ok.

Solutions:

1. Magnetic Coatings:

• These coatings typically contain magnetic metal particles such as iron powder, capable of absorbing and dispersing magnetic fields to some extent.
• It’s crucial to achieve uniform application of this coating for optimal results. It is to ensure that the coating thickness is sufficient to affect the magnetic field.

2. Soft Magnetic Powder Coatings:

• Special coatings contain particles of soft magnetic materials, such as mu-metal powder or iron-nickel alloy powder.
• These particles can enhance the coating’s ability to shield against magnetic fields. Especially effective in shielding low-frequency magnetic fields.

3. Multi-layer Composite Coatings:

• Composite coatings using multiple materials may enhance shielding effectiveness. For example, using a magnetic coating as the base layer and a wear-resistant, electromagnetically compatible material as the outer layer.
• By doing this, we’re making sure the coating stays tough and reliable.

4. Optimization of Coating Parameters:

• Adjusting the thickness, composition ratio, and coating area based on how strong and far-reaching the magnetic field is.
• Generally, increasing the thickness of the coating and altering the type and proportion of its magnetic materials can improve shielding effectiveness.

5. Experimentation and Testing:

• Conducting on-site testing after applying the coating is crucial. Magnetic field strength changes can be measured using a magnetometer to validate the shielding effectiveness.
• Based on the test results, adjust the thickness or material composition of the coating to achieve optimal shielding effectiveness.

Implement:

1. Choosing the Right Magnetic Coating：

• Select magnetic coatings containing high magnetic permeability metal particles of iron powder and nickel powder. They effectively absorb and disperse magnetic fields, reducing their impact on sensitive components.

2. Precise Application of Coatings:

• Coating Placement: Apply magnetic coatings at the specified magnetic coupling connector locations as requested by the customer.
• Coating Thickness: Adjust the thickness based on the intensity of the magnetic field. Generally, thicker coatings provide better shielding. We experimentally determine the optimal thickness, not exceeding 0.1 millimeters, based on customer requirements.
• Uniformity: Ensure even coating to avoid uneven shielding caused by variations in thickness.

3. Testing and Validation

• After applying the coating, measure the intensity changes of the magnetic field at sensitive component locations using a magnetometer.
• Evaluate the shielding effectiveness by comparing magnetic field data before and after the coating application.

4. Optimization and Iteration

• Adjust the coating thickness, application range, or material type based on test results. Iterate multiple times to achieve the best shielding effectiveness.

Outcome:

Reduced Magnetic Field Impact: Proper application of magnetic coatings significantly reduces the impact of magnetic fields on sensitive components on the PCBA. Mitigating low-frequency magnetic interference.
Maintained Device Functionality: Magnetic coupling functionality remains unaffected while ensuring the normal operation of other components on the PCBA.
Cost-Effectiveness: Compared to PCB layout redesign or using mu-metal shielding boxes, coating methods are more economical and operationally straightforward.

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Both are magnetic waterproof Pogo pin connectors! Magnets are N52, and waterproof is IP67.

For the project, we are fully involved in the customer’s design of the project! And provide our customers with the entire process from BOM, and Gerber files to the finished products.

Requirements

• We are looking for a small 4 and 6-pin waterproof magnetic pogo connector! For the development of a device! That consists of multiple parts connected with pogo pin connectors.
• It will be fitted in cases with insert molding and the width will be max 2 cm.
• We are trying to create a prototype for a sensor for outdoor use with IPX7!
  And we will insert over-molding it with most likely just a common thermoplastic.
• The sensor parts have a male pogo connector on 1 side and 1 female pogo connector on the other side.
• Is it possible to achieve a height of 1 cm, so with PCB and 2 connectors?

Solutions

Design Standards and Performance Metrics

• Waterproof Performance: Utilizes an IP67-rated waterproof design, capable of withstanding heavy rain, splashing, and brief immersion.
• Magnetic Connection: Incorporates high-quality N52 magnets to ensure stable connections. The magnets provide sufficient attraction to hold the connection while allowing for easy manual separation.
• Corrosion-Resistant Materials: Connector housing constructed of stainless steel to prevent corrosion issues that may arise from prolonged outdoor exposure.

Electrical and Data Transmission Design

• Power Delivery: Handles common power requirements of security cameras, powered by 12V. Capable of transmitting at least 2A of current through the magnetic connector to support continuous operation.
• Data Transmission Capability: Supports gigabit Ethernet data transfer speeds to accommodate high-definition video data needs.
• Interference Resistance Design: With its shielded cable construction, this ensures that external electromagnetic interference won’t disrupt the flow of data.

Mechanical and Physical Design

• Strength and Durability: Designed to withstand physical impacts, reinforced with metal materials in the housing.
• User-Friendly: Magnetic interface designed for one-handed operation, enabling easy connection or disconnection even in low light or while wearing gloves.
• Emergency Disconnect Function: Safely disconnects in emergencies such as device dragging to prevent equipment damage.

Convenience of Operation

• Convenient Connection: Provides power and Ethernet connection for fixed security cameras using magnetic connectors. Allows for quick installation and maintenance without concerns about wear and water damage to conventional plugs.
• Rapid Installation and Removal: During disaster response, rapidly deployable communication equipment utilizes magnetic connectors for quick setup and removal. Greatly enhancing response speed and flexibility.

Maintenance and Sustainability

• Easy Maintenance: Magnetic connector design reduces wear and tear from frequent connections, resulting in low maintenance costs.
• Sustainability Considerations: Environmental impact is considered in the design, utilizing recyclable materials and ensuring long-term durability to reduce replacement frequency.

Implement

Requirement Analysis and Planning

• Requirement Determination: Clearly define the power and data transmission requirements of the equipment as Ethernet and IP67 waterproofing.
• Selection: Confirm that the electrical characteristics of the magnetic connectors meet the equipment’s power and data rate needs. Ensure sufficient magnetic force for a stable connection.

Design and Testing

• Connector Design: The magnetic waterproof connector consists of a fixed female connector on the device and a movable male connector. Both parts are equipped with strong N52 magnets to guarantee a sturdy mechanical link, ensuring reliability in every connection.
• Waterproof Treatment: All exposed metal parts of the connector are made from corrosion-resistant stainless steel.
• Testing and Validation: Conduct waterproof and weather resistance tests in laboratory conditions, including immersion, exposure to extreme temperatures, and salt spray testing, to verify performance against specifications.

Production and Implementation

• Production: Upon confirmation that the design meets all specifications and customer-approved samples, commence mass production of the connectors. Quality control during production adheres to standards to prevent manufacturing deviations.
• Installation: Install connectors on devices, securing the female part to the device’s power and data interfaces. While the male part serves as part of the accompanying charger or data transmission cable.

Operation and Maintenance

• Personnel Training: Train installation and maintenance personnel timely. It is to ensure they understand how to handle magnetic connectors correctly and basic troubleshooting methods for connection issues.
• Regular Inspection: Establish a periodic maintenance plan to check if the magnetic properties of the connectors have weakened. Due to magnet aging or mechanical damage, and if the waterproofing performance of the housing is intact.

Result

Quick Deployment and Maintenance:

Magnetic connectors simplify installation and maintenance processes. Allowing customer’s devices to be quickly connected or disconnected, significantly improving on-site operational efficiency.

Assured Stable Connection:

Magnetic connectors provide stable and reliable power and data transmission. Greatly reducing signal interruptions or power supply issues caused by poor connections.

High Waterproof and Dustproof Performance:

IP67 waterproof design ensures equipment operates normally under harsh weather conditions. Effectively resisting the intrusion of rainwater and dust.

Enhanced Safety and Reliability:

The automatic disconnect feature of magnetic connectors prevents equipment damage caused by accidental pulling. Enhancing the overall safety of the system.

Reduced Overall Maintenance Costs:

Due to the durability and simplicity of operation of the connectors. Maintenance costs and equipment replacement frequency are reduced, resulting in overall cost savings.

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Problem Description:

• Previous solar panel deployment mechanisms relied on complex mechanical locking devices. Which are prone to failure in extreme space temperatures and microgravity conditions.
• Resulting in improper deployment or fixation of solar panels, affecting satellite power supply and mission continuity.

Root Cause Analysis:

• Traditional connection systems in space are significantly affected by thermal expansion and vibration, often leading to mechanical locking mechanism failures.
• In addition, these systems require complex manual or automatic deployment procedures, increasing operational risks.

Solution:

Introduce Johoty’s Pogo pin technology to design a new type of solar panel docking system. Which can automatically dock and has high fault tolerance:

• Pogo Pin Design: Customized a highly durable Pogo pin with an ultra-low and high-temperature operating range. Each Pogo pin is designed with high elasticity and sufficient contact force to ensure reliable contact even in microgravity environments.
• Modular Docking Interface: Each solar panel edge is equipped with a modular Pogo pin interface. Which can automatically find alignment and complete physical and electrical connections when the panel is automatically deployed.
• Redundant Design: Multiple Pogo pins are designed for each connection point to ensure that even if some pins fail due to rare events. They will not affect the overall stability and power transmission of the connection.

Implementation Process:

• System Design and Testing: Design and testing are first conducted in a simulated ground environment, including thermal vacuum testing and vibration testing. To confirm the design’s capacity to operate smoothly in the expected space environment.
• Manufacturing and Integration: After confirming that the design meets all performance indicators, mass production is carried out. Integration testing is conducted on the satellite body.
• Launch and Deployment: Launched into the designated orbit along with the satellite. The solar panel deployment mechanism is triggered by ground control commands, automatically completing the docking between panels.

Results:

This solar panel docking system using Pogo pins has performed well in multiple satellite missions:

• High Reliability: The success rate is close to 100%, and all deployed satellite solar panels have successfully deployed and operated stably.
• Simplified Operation: Greatly simplified the deployment operation of solar panels, reducing the complexity and risks of space missions.
• Cost-effectiveness: Reduced assembly time before launch and maintenance requirements after launch, reducing the overall mission cost.

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Problem Description:

• Traditional connectors are susceptible to vibration and temperature changes during high-speed UAV flight and harsh environments. Potentially leading to unstable or interrupted power connections, significantly impacting flight safety and system stability.
• The client needs a solution that offers quick connection, high reliability, space constraints, and durability to address these challenges.

Root Cause Analysis:

• Traditional connectors typically rely on physical contact between plugs and sockets. Which can lead to minor variations in contact during vibration or temperature changes, resulting in unstable connections.
• Additionally, due to the high-performance requirements of UAVs, significant currents need to be transmitted, which traditional connectors may not meet.

Solution:

1. Quick Battery Replacement:

• Integrating Pogo Pin connectors enables rapid battery replacement, reducing UAV ground time and enhancing mission continuity.
• Pogo pins between the battery and UAV body allow users or automated arms to swiftly replace batteries without tools.

2. Multifunctional Integrated Design:

• Integrate data and power transmission into a single Pogo Pin connector, reducing connector count and volume. This reduces space requirements, simplifies design, and makes the system more compact.
• Design a composite Pogo Pin containing multiple signal and power lines, each capable of transmitting data and power simultaneously. Thereby reducing overall interface count and size.

3. Self-Alignment Interface Design:

• Utilize magnetic or mechanically guided Pogo Pin connectors to ensure precise alignment, simplifying the connection process. Simplify equipment docking in confined spaces, ensuring connection accuracy and speed.
• Incorporate magnets or small mechanical structures into the Pogo Pin design to enable automatic alignment when nearing the docking interface.

4. Ultra-Small Pogo Pin Design:

• Smaller Pogo Pin sizes suit space-constrained applications while maintaining performance.
• Utilize microfabrication techniques to produce smaller diameter and lower height Pogo Pins. Ensure sufficient current carrying capacity and durability.

5. Optimized Multi-Point Contact:

• Design an optimized layout of multi-point Pogo Pins to provide more connection points in limited space. This design allows each connection point to bear smaller loads, reducing the risk of single-point failures.
• Distribute loads in the power connection area using multiple small Pogo Pins rather than relying on a single large connection point. Ensure the overall power supply remains unaffected even if one point fails.

6. Modular Quick-Release System:

• Adopt modular Pogo Pin connection design supporting quick insertion and removal, facilitating rapid UAV maintenance and battery replacement.
• Modular battery packs that are easy to access and disassemble, each utilizing Pogo Pin connectors for swift replacement without tools.

7. Enhanced Waterproof and Dustproof Features:

• Incorporate waterproof and dustproof designs into Pogo Pin connectors to enhance UAV adaptability in harsh environments and power system reliability.
• Install sealing rings around Pogo Pin interfaces or use other waterproof and dustproof materials. It is to ensure interfaces remain unaffected in various environments.

Execution Process:

• Requirement Analysis: Thoroughly understand the client’s requirements, including current transmission needs and environmental adaptability.
• Design Proposal: Based on client requirements and existing technology, design a connection solution based on high-current Pogo Pins. Conducting initial validation and assessment.
• Customized Design: Customize Pogo Pin design according to client-specific requirements, including material selection and spring force adjustment.
• Sample Production: Produce samples for experimental verification, ensuring they meet client requirements and expected performance.
• Testing and Validation: Rigorously test samples, including current transmission, vibration, and temperature change tests. Ensuring stable connections under various conditions.
• Mass Production: Based on test results, proceed with mass production and strict quality control to ensure stable and reliable product quality.

Outcome:

• We successfully designed and provided a high-performance UAV power connection solution for the client, based on high-current Pogo Pin technology. Characterized by high reliability, stability, and durability, capable of maintaining a stable power supply under extreme conditions.
• The client is highly satisfied with our solution and has applied it to their UAV project, achieving excellent results and feedback.

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Problem Description:

• Due to limited space for aviation electronic devices, traditional connectors often fail to meet their needs. Additionally, vibration and temperature changes in aviation environments pose challenges to connector stability.
• The client requires a solution to stably connect power and data within limited space.

Root Cause Analysis:

• In limited space, traditional connector sizes and shapes may not meet the design requirements of aviation electronic devices.
• Moreover, traditional connector typically relies on physical contact between plugs and sockets. Which can lead to minor variations in contact during vibration or temperature changes, resulting in unstable connections.

Solution:

1. Vertical and Horizontal Combination Connection:

• Enhance connection flexibility and space utilization by vertically and horizontally combining side-mount Pogo Pin connectors. Connections can be made in different directions within limited space, enhancing design flexibility.
• Design Pogo Pin arrangements with both vertical and horizontal insertion methods. This is to facilitate flexible connections for each circuit board inside the equipment.

2. Low-Profile Design:

• Develop low-profile right-angle Pogo Pin connectors to reduce protrusion height. Ideal for height-restricted applications, like compact aviation electronic compartments.
• Use low-height Pogo Pins and optimize internal spring structures to achieve designs with both height elasticity and minimal space occupation.

3. Multifunctional Integrated Design:

• Integrate power and data transmission into the right-angle Pogo Pin connector. Reduce connector count, overall design complexity, and volume.
• Design each contact point of the Pogo Pin to transmit both power and data.
• Achieving multifunctional integration through composite materials and high-precision processing technology.

4. Self-Locking Mechanism:

• Incorporate a self-locking mechanism into right-angle Pogo Pin connectors to prevent detachment even in high-vibration environments. Enhance connection stability and reliability, suitable for vibrations and impacts in aviation environments.
• Design a small mechanical locking structure that automatically locks when the Pogo Pin is inserted. Requiring specific operations to unlock and detach.

5. Modular Interface Design:

• Adopt modular side-mount Pogo Pin connectors supporting quick connection and replacement between different modules. Improve maintenance efficiency, allowing rapid replacement or upgrading of various modules in the equipment.
• Design a standardized modular connection framework, with each module using the same side-mount Pogo Pin interface, facilitating quick module replacement through simple push-pull operations.

Execution Process:

• Requirement Analysis: Fully understand client-specific requirements for the connection solution, including space constraints, power, and data transmission needs.
• Design Proposal: Based on client requirements and existing technology, design a right-angle Pogo Pin-based connection solution and conduct initial validation and assessment.
• Customized Design: Customize side-mount Pogo Pins according to client-specific requirements, including material selection, size, and shape adjustments.
  Sample Production: Produce samples for experimental verification, ensuring they meet client requirements and expected performance.
• Testing and Validation: Rigorously test samples, including connection stability, vibration, and temperature change tests, ensuring stable connections under various conditions.
• Mass Production: Based on test results, proceed with mass production and strict quality control to ensure stable and reliable product quality.

Outcome:

• We successfully designed and provided an aviation electronics right-angle Pogo Pin solution for the client. Featuring a compact design, stable connection performance, and good vibration resistance. Meeting power and data connection needs within limited space.
• The client is highly satisfied with our solution, successfully applying it to their aviation electronic devices, achieving excellent results and feedback.

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Problem Description

In the client’s existing smart bracelet design, board-to-board connections encounter common issues, including:

• Unstable connections, prone to mechanical vibrations and everyday wear.
  Electrical signal interference affects the accuracy and speed of data transmission.
• High design complexity, leads to increased assembly costs and maintenance difficulty.

Solution

1. Design Improvements

• Use low-impedance, high-signal integrity connectors: We opt for micro Pogo pin connectors with excellent electrical performance and high-density metal contact points. This is to minimize signal interference and enhance connection reliability.
• Utilize flat-bottomed Pogo Pins connection technology: Based on the client’s specific application scenarios, we introduce flat-bottomed Pogo pins. It is to ensure proper connector alignment, reduce size constraints, and ensure stable electrical contact.

2. Materials and Manufacturing

• Corrosion-resistant materials: Incorporate materials with better corrosion resistance, such as gold plating, to improve connector durability and long-term performance.
• Precision manufacturing processes: Employ precision machining techniques to ensure that each component meets strict engineering standards for size and shape.

3. Electrical Design

• Ultra-low contact impedance: Introduce more effective low-impedance outbound measures in the design, achieving as low as 15mΩ to enhance charging speed and data transmission.
• Optimize circuit layout: The client also improves PCB design accordingly, using differential signal transmission to reduce signal loss and interference.

4. Software and Firmware

• Error detection and correction protocols: Implement advanced error detection and correction mechanisms in the data transmission protocol to ensure data integrity and accuracy.
• Firmware updates and management: Provide regular firmware updates to optimize connectivity performance and enhance device security.

Implementation Steps

1. Prototype development and testing: Design and manufacture improved connector prototypes, conducting comprehensive tests to evaluate their mechanical and electrical performance.
2. User testing and feedback collection: Deploy prototypes to a small group of users, gather feedback, and iteratively optimize the design.
3. Mass production readiness: After testing and validation, adjust the production line to accommodate the new design and manufacturing processes and commence mass production.
4. Market promotion and after-sales support: Debut the fresh product line with a commitment to delivering extensive after-sales assistance and repair options for maximum customer gratification.

Expected Results

• Improved stability and reliability: The newly designed connectors should significantly enhance connection stability and interference resistance.
• Cost-effectiveness: While initial development and manufacturing costs may increase, reliable connections reduce maintenance and replacement costs, improving overall cost-effectiveness.
• Increased user satisfaction: Enhanced device performance and reliability will elevate user satisfaction and market acceptance.

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Problem Description:

• Stability Issues: Traditional pin-type connectors suffer from poor contact due to frequent use, affecting the normal functioning of the equipment.
• Inefficient Operation: In emergency medical situations, operators need to quickly and accurately connect or disconnect power and data interfaces. Traditional connectors add time costs due to their complex operation.
• High Maintenance and Replacement Costs: Connectors need to be replaced regularly due to mechanical wear, increasing the overall maintenance costs of the equipment.

Reason Analysis：

• Mechanical Interface Wear: Long-term repeated insertion and removal cause physical interface wear, affecting connection quality.
• Risk of Mis-operation: In high-pressure environments, complex mechanical connections may lead to mis-operations, affecting equipment performance and patient safety.
• Environmental Factors: Environmental factors, such as dust and moisture may erode electrical interfaces, affecting connector performance over time.

Customer Requirements：

• High Reliability: The new connection system is required to withstand long-term use without affecting performance. Especially in terms of contact reliability and electrical stability.
• Ease of Operation: The new system needs to support quick, consistent connection and disconnection, even by non-professionals in emergencies.
• Low Maintenance Costs: The new connector should reduce maintenance requirements due to wear, thereby lowering long-term operational costs.
• Compliance with Medical Standards: All designs and materials must comply with strict international medical safety standards, such as ISO 13485.

Solution:

1. Design Improvement

• Adoption of Magnetic Connector: Introduce magnetic male-female attraction to automatically align and connect, improving connection speed and accuracy.
• Optimization of Pogo Pin Design: Use durable materials and increase the number of contact points to enhance electrical connection stability and durability.

2. Materials and Manufacturing

• High Wear Resistance Materials: Use corrosion-resistant, high-wear materials to manufacture Pogo Pins and interfaces, such as gold-plated copper alloys, to increase product lifespan.
• Precision Machining Technology: Ensure the precise manufacturing of all connector components to improve reliability and reduce maintenance requirements.

3. Safety and Performance

• Compliance with Medical Standards: Ensure all components and designs meet international safety standards for medical devices.
• Electromagnetic Compatibility Testing: Conduct rigorous EMI/EMC testing to ensure the connector does not interfere with the normal operation of the surgical instruments.

Execution：

• Prototype Development and Testing: Design and manufacture prototypes of magnetic pogo pin connectors, and conduct electrical and mechanical performance testing.
• Clinical Evaluation: Assess the functionality and reliability of the magnetic pogo pin connector through clinical trials conducted in real medical settings.
  Production Optimization: Optimize product design based on trial feedback and prepare for mass production.
• Customer Validation and Approval: Obtain final approval from the customer and begin mass production, gradually implementing them in the customer’s surgical instruments, highlighting improved operational efficiency and reduced maintenance costs.

Results：

• Improved Operational Efficiency: Magnetic pogo pin connector simplifies the operation process, significantly reducing equipment setup and dismantling time.
• Enhanced Equipment Reliability: Magnet tic pogo pin connector reduces mechanical wear, improving the overall reliability of the equipment.
• Reduced Maintenance Costs: Due to reduced maintenance requirements and connector replacement frequency, overall maintenance costs significantly decrease.

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Problem Description:

The current portable ventilator’s charging interface faces several issues, including:

• Susceptibility to mechanical wear and environmental factors.
• Unstable connection during charging and data transmission.
• The docking of the charging interface requires precise alignment, causing inconvenience for patients or medical staff.

Root causes:

1. Design and Mechanical Docking Issues：

• Alignment Difficulty: Traditional non-magnetic connectors require precise alignment for effective connection. Which can be challenging in emergencies or when operated by non-professionals.
• Physical Wear: Frequent physical insertion and removal can lead to mechanical wear, reducing the interface’s lifespan and reliability.

2. Electrical Connection Reliability

• Unstable Electrical Contact: Mechanical tolerances, wear, or impurities can affect the contact quality of contact pins, leading to interruptions in charging and data transmission.
• Current Carrying Capacity: The design of contact pins needs to be able to carry sufficient current to meet the requirements of medical equipment. Inadequate design may result in inefficient charging.

3. Material Selection

• Corrosion and Oxidation: If the material of the contact points is prone to oxidation, its conductivity may decrease over time.
• Elastic Fatigue: If the material of the spring in the contact pin weakens over time due to prolonged use, it may affect the stability and durability of the connection.

4. Environmental Factors

• Environmental Pollution: Dust, dirt, or liquids may penetrate the connector, affecting electrical performance.
• Temperature and Humidity: The performance of materials could be affected by extreme temperatures and humidity. Such as causing material expansion or contraction, and impacting electrical contact.

Solution：

1. Design Improvements

• Magnetic suction feature: Implement a magnetic adsorption design to enable automatic alignment and fixation of the connector. Simplifying the operation process and reducing docking failures.
• Pogo Pin optimization: Enhance the design of the Pogo Pins to increase the contact force of the contact points. Improving the reliability and durability of electrical connections.

2. Materials and Manufacturing

• High-wear-resistant materials: Select corrosion-resistant and highly wear-resistant materials. Such as gold-plated copper alloys, to extend the connector’s service life.
• Precision manufacturing: Utilize high-precision manufacturing techniques to ensure the precise installation and alignment of Pogo Pins and magnets.

3. Electrical and Mechanical Design

• Enhanced current carrying capacity: Design the Pogo Pins to support higher current transmission to meet the ventilator’s power requirements.
• Anti-mis-insertion design: Ensure the connector can only be connected perfectly through unique magnetic pole configurations. Avoiding damage caused by mis-operation.

4. Safety and Standards

• Compliance with medical standards: Ensure all designs and materials comply with medical device standards, ISO 13485.
• Electrical safety testing: Conduct rigorous electrical safety testing, including short circuit, overload, and stability tests. To ensure the device operates safely under various conditions.

Implementation Steps：

• Prototype development: Design and manufacture connector prototypes, and conduct initial tests of their physical and electrical performance.
• Clinical trials: Conduct clinical trials in actual medical environments to validate their usability and reliability.
• Optimization and iteration: Continuously adjust and refine the design based on clinical input to achieve the best possible product performance.
• Mass production and promotion: Upon finalizing the design, initiate small-scale production and then mass production. While providing comprehensive technical support and services to the client.

Expected Results：

• Improved ease of operation: The magnetic suction design simplifies the operation process, enhancing the user experience for patients and medical staff.
• Enhanced connection stability: The optimized Pogo Pin interface enhances charging stability.
• Reduced equipment maintenance costs: Due to material and design improvements, maintenance costs and equipment failure rates are reduced.

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Issues:

• Existing contacts exhibit instability under high currents during charging. This instability may lead to increased contact resistance, heating, and other safety concerns.
• The client asks us for a solution to ensure stable and safe current transmission at 800A, maintaining good contact and reducing faults.

Root Cause Analysis:

• Excessive current causing instability: Generates localized high temperatures, leading to deformation of contacts or reduced contact area.
• Material and design issues: Potential design flaws causing performance degradation under high currents.
• Environmental factors: The usage environment of the charging interface may involve vibration, humidity, temperature variations, etc.
• Improper contact surface treatment: Could result in poor contact or increased contact resistance.

Client Requirements:

• Stability: Ensure stable contact under high currents, avoiding localized high temperatures or poor contact.
• Safety: Ensure the charging process is safe, without risks of heating or fire hazards.
• Durability: Maintain stability and safety under prolonged usage and high-frequency insertions and withdrawals.
• Adaptability: Ability to withstand environmental factors such as vibration, humidity, and temperature variations.

Solution:

• Material and design optimization: Selection of highly conductive, high-temperature-resistant, and wear-resistant materials, designing 800A high-current pogo pins.
• Enhanced heat dissipation design: Effective heat dissipation design to prevent localized high temperatures.
• Surface treatment optimization: Employing gold plating to improve contact performance, reduce contact resistance, and enhance corrosion resistance.
• Strict quality control: Stringent quality management, covering detailed material examination, constant supervision of production procedures, rigorous scrutiny of finished goods, and more. Ensuring the consistency and trustworthiness of each pogo pin.

Effective Implementation:

• Thorough understanding of the client’s evolving needs and expectations to ensure the solution meets their requirements.
• Strict adherence to the client’s requirements and standards in production, testing, and inspection. To ensure quality and performance meet the client’s expectations.

Results:

• Stable performance: The Pogo Pin maintains stable contact under high currents, ensuring the safety and stability of the charging process.
• Safety enhancement: The client avoids safety hazards, reducing the likelihood of accidents.
• Long-lasting durability: Maintains stability and reliability under prolonged usage and high-frequency insertions and withdrawals.
• Solution satisfaction: Meets the client’s personalized requirements for Johoty’s Pogo Pin performance and quality, enhancing client trust and satisfaction.

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Issues:

• The OBD interface currently used by the client provides basic diagnostic functions. However, under high-speed driving or complex driving conditions, it may not provide sufficient real-time data.
• This results in inaccurate or incomplete diagnostic results. The client seeks improvements to the OBD interface to enhance the accuracy and reliability of real-time diagnostics.

Root Cause Analysis:

• Inadequate data transmission rate: Possibly limited by data transmission rate, unable to transmit large amounts of data in a short time. Leading to delayed or incomplete real-time diagnostic results.
• Poor contact: Issues such as insufficient contact area or oxidation may exist.
  Signal interference: In complex automotive electronic systems, signal interference issues may arise.
• Imperfect software algorithms: In addition to hardware issues, there may be software algorithm imperfections.

Client Requirements:

• Increase data transmission rate: Enhance data transmission rate to ensure the transmission of large amounts of data in a short time. Supporting faster real-time diagnostics.
• Improve contact quality: Enhance the OBD interface to ensure good contact quality and reduce instances of poor contact.
• Interference resistance: Improve interference resistance to ensure stable data transmission in complex automotive electronic environments.

Solution:

• Optimize contact design: We optimize the design of Pogo pins for the OBD interface connectors, ensuring adequate contact area. And appropriate contact pressure, and using corrosion-resistant materials to reduce instances of poor contact and oxidation.
• Increase transmission rate: Utilize highly conductive materials and optimized structural designs to enhance the transmission rate of Pogo pins.
• Enhance interference resistance: Employ interference-resistant materials and technologies, designing and processing Pogo pins to enhance their interference resistance.
• Size optimization: Carefully design dimensions, shapes, materials, etc., to ensure full compatibility with the client’s OBD interface design and requirements.

Effective Implementation:

• Study client needs and expectations to ensure the provided solution meets client requirements.
• Strictly control quality during production to ensure the quality of Pogo pins meets client standards and requirements.
• Necessary tests and inspections, including contact pressure tests, corrosion resistance tests, transmission rate tests, etc. To verify the performance and reliability of Pogo pins.

Customer Satisfaction:

• Improved diagnostic accuracy: Optimized Pogo pin design and manufacturing quality ensure good contact quality. Reducing the impact of poor contact and oxidation on data transmission, thereby improving the accuracy of real-time diagnostics.
• Enhanced stability: Increased transmission rate and interference resistance ensure stable data transmission of Pogo pins in complex environments. Reducing data transmission delays and fluctuations, thus enhancing the stability of real-time diagnostics.
• Professional service: Providing customized solutions to meet client’s personalized requirements for Pogo pin size, shape, material, etc. Enhancing client trust and satisfaction with the factory.

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Problem Description:

• Unstable Connections: When connecting audio-visual devices, there may be instances of unstable connections or disconnections. Lead to interruptions in playback or video stuttering.
• Low Transmission Rates: When transmitting large amounts of audio-visual data, transmission rates may be limited, resulting in unclear video quality or audio delays.
• Compatibility Issues: There are compatibility issues with different devices, causing them to be unable to connect properly or fully utilize their functionalities.
• Complex User Operations: Users encounter complexity when connecting multiple devices or switching between different input sources.

Root Cause Analysis:

• Poor Connector Design: The current connector design is inadequate, leading to unstable connections or restricted transmission rates.
• Unreasonable Transmission Protocols: The transmission protocols used may not be suitable for transmitting large amounts of audio-visual data.
• Poor Device Compatibility: The current connectivity solution does not adequately support different manufacturers’ and models’ audio-visual devices.
• Unfriendly User Interface Design: There may be issues with unfriendly user interface design or unclear operational procedures.

Client Requirements:

• Stable Connections: Ensure stable audio-visual connections to avoid interruptions or video stuttering.
• High-Speed Transmission: Support high-speed transmission of audio-visual data to guarantee clear video quality and no audio delays.
• Good Compatibility: Ensure compatibility with various audio-visual devices to maintain stable connections and fully utilize device functionalities.
• Simple and User-Friendly Operation Interface: Provide a simple and user-friendly interface and operational procedures for users to easily and quickly connect and operate audio-visual devices.

Solution:

• Optimized Connector: We have optimized the design of audio-visual connectors using high-quality Pogo pins to ensure stability and durability. Reducing friction and resistance during connection, thereby enhancing stability.
• Increased Transmission Rates: High-speed transmission is supported by using highly conductive materials and optimized structures to improve the transmission rate of audio-visual data. Ensuring high-definition video quality and no audio delays.
• Enhanced Compatibility: Different types of Pogo pin connectors are designed, considering the interface specifications and communication protocols of different devices. Ensuring stable connection and communication with various devices.
• Improved User Operation Experience: We provide clear indicator lights and simple plug-and-play operations, greatly enhancing the user experience and convenience.

Effective Execution:

• Researching customer needs and expectations to ensure that the provided solution meets customer requirements.
• Strictly controlling product quality to ensure that the quality of Pogo pins meets customer standards and requirements.
• Conducting stability tests, transmission rate tests, compatibility tests, etc. To guarantee the effectiveness and dependability of the Pogo pin connectors.

Results that Satisfy the Client:

• Enhanced User Experience: Optimized connectors enable users to easily enjoy high-quality audio-visual entertainment.
• Improved Connection Stability: Ensuring the stability and durability of connectors reduces connection interruptions and data transmission errors.
• Enhanced System Performance: High-speed transmission and highly compatible connectors enhance the overall performance of in-car entertainment systems. Making audio-visual data transmission smoother and more stable.
• Increased Competitiveness: Empowering clients to enhance product competitiveness reinforces their market position and augments their reputation.

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Issue Description:

• In the client’s robot products, the 20A Pogo Pin is used as part of the connectors for electronic control systems and actuators. However, the client found stability issues with the Pogo Pin when the robot operated on charge for more than 3 minutes.
• This includes unreliable connections, disconnections, or unstable electrical connections. Negatively impacting the robot’s performance and reliability.

Reasons Analysis:

• Firstly, prolonged high-load operation may cause wear on the contact surfaces of the Pogo Pins, weakening their connection capability.
• Secondly, the design of the Pogo Pins may not be robust enough to withstand the vibrations and impacts during robot movement.
• Additionally, factors such as poor installation and adverse environmental conditions may also affect the stability of the Pogo Pins.

Client Requirements:

• Resolve the issue of unstable Pogo Pin connections. Ensuring that the robot can maintain stable connections for over 3 minutes at 20A current.
• Provide a reliable solution to improve the durability and stability of the Pogo Pins. While reducing maintenance costs and system downtime.
• Some improvements are needed, including optimizing the design of the Pogo Pins, selecting more suitable materials, and improving installation methods. To secure enduring, trustworthy functionality in the complex working environments of the robots.

Solution:

1. Design Optimization:

• Collaborate with the engineering team to fine-tune the design in alignment with the precise needs of the robots. Including selecting appropriate materials, sizes, and shapes.

2. Material Selection:

• Choose high-quality, durable beryllium copper to ensure good conductivity and durability of the Pogo Pin.

3. Precision Machining:

• Utilize advanced machining equipment and technology to ensure manufacturing precision, surface smoothness, and dimensional accuracy of the Pogo Pins.

Execution:

1. Requirements Analysis:

• Thoroughly understand the working environment, usage conditions, and connection requirements of the robot system.

2. Material Selection:

• Ultimately select high-quality, durable beryllium copper to ensure good conductivity and corrosion resistance of the Pogo Pin.

3. Quality Control:

• Implement strict quality control, combining automated inspection equipment and manual sampling inspections to ensure each pogo pin high quality.

4. Performance Testing:

• Conduct electrical characteristic tests and mechanical performance tests to ensure the stable connection and conductivity of the Pogo Pin.

5. Production Planning and Logistics Management:

• Reasonable production plans to ensure timely completion of orders and ensure timely delivery to customers through effective logistics management.

Customer Satisfaction Results:

• Stable Performance: The client obtained the expected 20A Pogo Pin. Can maintain stable and reliable performance and good conductivity even after 3 minutes of operation at 20A current. Ensuring the continuous operation of the robot system.
• Long-term Reliability: The 20A Pogo Pin, precision machined and quality controlled, has high durability. It’s crafted to withstand prolonged usage and overcome any environmental hurdles.
• The client has confidently integrated the Pogo Pin into the robot system. Minimizing system downtime and maintenance outlays by removing the requirement for regular replacements or upkeep.

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Issues:

• Unstable connections: The traditional screw-fixed connectors in the existing system often loosen due to vibration and prolonged operation. This affects the stability of the system and the accurate transmission of signals.
• Maintenance difficulties: Due to the inadequate design of connectors, replacement and maintenance tasks are time-consuming, leading to increased production downtime.
• Inaccurate positioning: After component replacement or maintenance, the precision of repositioning is insufficient, resulting in decreased machine efficiency and unstable output quality.

Root Causes:

• Outdated connection methods: The utilized connection technology fails to meet the requirements of high-frequency operations and high precision. The traditional screw connections are susceptible to physical wear.
• Inefficient design for maintenance: Insufficient consideration for the requirements of rapid maintenance and module replacement.
• Lack of adaptive design: Inability to effectively adapt to the continuously changing working environment and conditions in the production line.

Client Requirements:

• High stability: Resistance to prolonged vibration, temperature variations, and humidity.
• Rapid maintenance: Support for quick replacement and maintenance to minimize machine downtime and enhance production continuity.
• Precision positioning: Higher precision in positioning.
• User-friendly operation: Simple and understandable operation and maintenance to reduce training costs and operational errors.

Solution:

1. Design

• Customized pogo pins: Designed with different diameters, lengths, spring forces, and voltage resistance levels to meet various current and signal transmission requirements.
• Modular connection design: Allows for quick plug-and-play, stable electrical connections, mis-insertion protection, and IP67 dust and waterproof functions.

2. Manufacturing

• Manufacture pogo pins using high-quality materials and precise production techniques. Strict quality control ensures compliance with specifications.

3. Testing

• Test electrical performance, mechanical lifespan, and environmental adaptability to ensure stable operation.

Implementation Details:

• Requirement confirmation: Thorough understanding of the current system configuration and issues to confirm improvement requirements.
• System design and prototype development: Design system solutions and develop prototypes.
• Prototype testing and adjustments: Test prototype performance, and adjust design until all performance indicators are met.
• System deployment and training: On-site installation and configuration. Training on system operation and maintenance.
• Continuous monitoring and support: Continuous technical support and system monitoring to ensure long-term stable operation, with necessary upgrades and optimizations.

Results to Satisfy the Client:

• Enhanced production efficiency: Significantly reduced equipment maintenance time, improving the operational efficiency of production lines.
• Increased system stability: Ensured reliability of connections, reducing equipment failures caused by connection issues.
• Ease of operation: Operators are quickly acclimating to the system, minimizing the likelihood of operational mishaps.
• Increased customer satisfaction: Regular performance assessments and immediate technical support. Ensure customer satisfaction with the system’s use, and enhance trust and cooperation with the client.

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Issues:

• Unstable connections: Physical connections between sensors and control systems intermittently fail, leading to interruptions in data transmission.
• Low charging efficiency: The limited battery life of some wireless sensors results in frequent replacements or recharging, affecting production efficiency.
• Data latency: The speed of data transmission from sensors to the control center fails to meet the real-time monitoring requirements, impacting timely decision-making.

Root Causes:

• Technological lag: Existing connection and charging technologies have failed to keep pace with the latest industrial automation standards. This results in inefficiency and unstable connections.
• Improper system integration: Inadequate design for integrating sensors with control systems leads to unstable data transmission and charging issues.
• Maintenance challenges: Maintenance of sensor systems is cumbersome. Especially during charging and component replacement, requiring extensive manual operations.

Client Requirements:

• Connection stability: Reliable and continuous data transmission is required.
• Efficient charging solution: Support for rapid charging, and more efficient power management solutions to extend working hours and reduce maintenance frequency.
• Real-time data transmission: Data transmission speed needs to meet real-time monitoring requirements to facilitate quick responses to production line changes.

Solution:

1. Design

• Customized pogo pin connectors: Design durable pogo pin connectors to achieve stable and reliable connections between sensors and control systems.
• Integrated charging function: Integrate charging interfaces, allowing sensors to recharge automatically during connection, simplifying operations and improving charging efficiency.

2. Manufacturing

• High-standard production: Produce high-quality pogo pin according to strict industrial standards, ensuring stable operation in harsh industrial environments.

3. Testing

• Comprehensive testing: Conduct continuous connection-disconnection tests, electrical performance tests, and long-term durability tests on pogo pin connectors. To ensure their performance meets expectations in real working environments.

Execution Details:

• Understanding client requirements: Understand the client’s specific technical requirements and on-site environment to design pogo pin solutions.
• Sample production and preliminary testing: Manufacture samples and conduct preliminary testing in laboratory environments to evaluate their performance and reliability.
• On-site pilot and feedback adjustments: Implement pilot projects at the client’s factory and adjust the design based on on-site feedback.
• Large-scale deployment: Begin deploying improved connection and charging systems on all relevant equipment based on pilot results.
• Training and technical support: Provide training for the client’s technical team to ensure effective operation and maintenance of the new systems. And offer ongoing technical support.

Satisfactory Results for the Client:

• Improved reliability of connection and charging: Significantly enhanced connection stability and charging efficiency, reducing equipment downtime.
• Enhanced real-time and accurate data transmission: Ensured rapid and reliable data flow from sensors to control systems, supporting more efficient production decisions.
• Reduced maintenance costs and extended equipment lifespan: Simplifying maintenance processes and improving overall equipment efficiency. Maintenance costs have been significantly reduced, and equipment lifespan has been extended.

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