2013 COPYRIGHT BY EMDEP Group - No reproduction or disclosure is permitted without written prior consent

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Terminal Position Detection
Position Sensor Probes
2013 COPYRIGHT BY EMDEP Group - No reproduction or disclosure is permitted without written prior consent 2013-04-21 Page 2
Terminal Position Detection
Introduction
Detection of delay terminals (TPO) is one
of the most problematic issues on harness
manufacturing. EMDEP has several
technical solutions to detect this defect.
Each of them must be used after a detailed
analyze of all the involved terminal-housing
characteristics.

One such solution is using EMDEPs
Terminal Position Detection test module
fitted with special positioning sensor test
probes.

The table on the next page illustrates the
various technical solutions that EMDEP
has for TPO or badly inserted terminals in
the connector housing.
Electrical contact
In general it is possible to define the
displacement range whereby it is expected
that the electrical contact to the terminal
should be achieved.

Looking at the below figure, both terminals
are making electrical contact with the Test
Probe, but the terminal on the right is not
correctly inserted and it will result in a
potential quality defect.

2013 COPYRIGHT BY EMDEP Group - No reproduction or disclosure is permitted without written prior consent Page 3
Terminal Position Detection
How it works
Using position sensor pins, we can have not only a continuity test
between pin and terminal, but also a potentiometric measure
depending on the height of the terminal.

This enables a position test of the terminal, having different resistance
according with the position of it.

It is not necessary lose the continuity to detect the incorrect position of
the terminal.

2013-04-21
2013 COPYRIGHT BY EMDEP Group - No reproduction or disclosure is permitted without written prior consent Page 4
Terminal Position Detection
A B C D E
Typical Travel contact 1 to 1,5mm 0,4 to0,8mm Adjustable Adjustable Adjustable
Probe force 1 to 3N 1 to 3N 5 to 20N 1 to 3N 1,5N
Unlocked terminals No Some Yes Yes Yes
Risk of excesive force NO NO YES NO NO
Clear contact area required NO NO YES YES NO
Min. Distance between
centers
2,2 mm 2,2 mm 2,54 mm 3,3 mm 2,54 mm
A B D E F
Test Probe type Description
A Std. Test probes Screwed pins
B Step Probes Pins with collar which delimites the
contact travel.
C Pushback probes Make force against terminal to push
them out.
D HLC Detection of the right position of the
terminal retainer
E Position Sensor Measures the lenght of the contact
2013-04-21
2013 COPYRIGHT BY EMDEP Group - No reproduction or disclosure is permitted without written prior consent Page 5
Terminal Position Detection
The Terminal Position Detection modules are
fully compatible with the current EMDEP
Wintestem hardware (analog type).

Also standard C6 interface card will be use.

The only requirement is the necessity to use
two additional test points per cavity for
codifying the position.

EMDEP Wintestem Application Software is
ready to have the appropriate parameters
defined in terms of the expected position and
tolerance for each terminal pin individually.

This can be found in the options for the
Connector Definition menu.

2013-04-21
2013 COPYRIGHT BY EMDEP GROUP - No reproduction or disclosure permitted without prior written consent