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Make connector housings fill all pins with empty slots where unused pins go.
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Description

For manufacturability, we recommend that the connector housings match the pin number of the headers that they plug into. This makes it less likely that a mistake will be made during assembly, since there are fewer possible ways to plug it in.

Event Timeline

kent created this task.Aug 9 2018, 3:11 PM
kent triaged this task as Normal priority.
tutley added a subscriber: tutley.EditedAug 9 2018, 3:13 PM

@kent we should also use "dummy" pins to ensure there is a good friction fit with the connector

edit: sorry i guess that is kind of mentioned in the title

west added a comment.Aug 9 2018, 3:20 PM

@kent This is only applicable with the servo signals, I think its acceptable to use maybe like a 10 pin double stack housing but using a 24 pin double stack seems excessive

logan added a comment.Aug 13 2018, 9:24 AM

I think for the servo signal we could even get away with an 8 pin double stack filled with dummies. The servo signals are on the 3rd pinset from the left of the board on the 24 pin header, and an 8 pin would go one row past that position.

west added a comment.Aug 13 2018, 9:32 AM

@logan we will implement that on the servo signals

logan added a comment.Aug 13 2018, 9:42 AM

@west are all of the partially filled headers on the board servo signals? I see the yellow and blue that is on the 24 pin header, but there's another cut connector towards the top with 2red/2black, and then a 4 pin jammed clip-up into a 10 pin header

west added a comment.Aug 13 2018, 9:43 AM

@logan that was temporary until we received the new archims. They now have a housing, the servos are now the only ones without

west closed this task as Resolved.Aug 27 2018, 7:20 AM

updated with the new archim. all pins are illed

alexei changed the edit policy from "All Users" to "LulzBot Hardware Products (Project)".Aug 27 2018, 7:26 AM

We have seen a couple instances so far (2 through email, and 1 over phone) of the 10 pin header coming loose from the Archim board during shipping. This is leading to false errors from the filament sensor and their second extruder not lowering right out of the box. When I mentioned this in MER meeting it was suggested that adding additional pins to the blank pin slots would help to improve the fit of this connection and hopefully help prevent this issue in the future. Could we reconsider adding pins to the blank slots on this ten pin header to stabilize it?

Ticket ID's related to this issue:
205,011
204,994

@bowman @cmerot

kent reopened this task as Open.Jun 10 2019, 10:06 AM

I looked at the drawing and it's not clear that there should be blank pins there, not only that, but it not particularly efficient for production to build them that way. Probably best would be to have a latching connector that only plugs in one way like the motors or thermistors. This would also solve this issue: https://code.alephobjects.com/T3426. That fix is a little harder though because it would require an Archim rev. Another thing we could try is using a little hot glue on the connector housing where it touches the board. If done right, this will hold it in place without being too difficult to remove. @mjpelletier I'm interested in any suggestions you have to mitigate this issue.

DaniAO added a subscriber: DaniAO.Jun 10 2019, 10:07 AM

FYI- any changes to the Archim means we go back to EMI and UL testing...

Hot glue is something that is frequently used for this purpose, but would be very tedious in this case given the size of the header being attached to and close proximity of other board mounted components.
If we find a location suitable for this, it may be better to attach and glue this connector prior to placing the Archim in the box in order to prevent other wires from being burnt by the glue gun tip.

Would a glob just to the right of this connector, placed on the exposed pins/against the connector be an acceptable option?

The last option may not require a major change in the order of installation as noted above.

I agree that adding dummy pins is not a very efficient way to build these for production, however we have done dummy pins in the past, and i think this is a better option than hot glue.

The connector will only require 4 dummy pins. which are the EL-MS0059 (female molex) pins. These are not hard to install or remove if need be. The most time consuming part will be pre crimping the pins

And overall I think that dummy pins will be less time consuming that dealing with hot glue

kent updated the task description. (Show Details)Jun 18 2019, 8:15 AM
kent reassigned this task from kent to Steven.Jun 19 2019, 7:12 AM

@Steven I'm assigning this to you to coordinate the update to the drawing based on the brief discussion we had in NPI.

kent added a comment.Jun 19 2019, 8:02 AM

btw, I'm confident that a design like this https://code.alephobjects.com/T3306#64439 would prevented issues like https://code.alephobjects.com/T3307#140910 due to the fact that the wires with latching connectors are attached to and supported by the wires without latching connectors so they are held in place better. This is essentially the same fix that Mark is suggesting now for https://code.alephobjects.com/T7785, just for all the wires instead of just two.

Steven reassigned this task from Steven to west.Jun 20 2019, 12:51 PM

@west have you already made the changes to this in drawing to add the dummy pins? If not, can you please do so?

west added a comment.Jun 20 2019, 12:54 PM

@Steven, i wasnt aware that we were moving forward with that change. I believe this would require a change order unless this is just verifying that it would work in the first place

Ah, I assumed there was already a change request already in progress. @kent @DaniAO is there a change order related to this ticket?

west added a comment.Mon, Jun 24, 7:23 AM

I pushed the drawing here so that I dont lose it while a change order is being made

I just encountered a client who is having a issue with his actuators not moving when he is doing a dual print. Still waiting to get pics of the Archim but I was able to recreate the issue in house.

@jspreitzer how did you recreate the issue?

I removed the cable connection for Servo 1 and Servo 2 (The cable below the LCD cable on the Archim board) Then I powered on the printer and tried to do a filament change and just switch between the two extruders. Extruder 1 remained in the lowered position and when I would select extruder 2 it would not raise and extruder 2 would not lower.

@jspreitzer ah ok i just wanted to make sure i understood correctly

@DaniAO do you know if a change order been made for this yet?
i can get one started if need be

@tutley not that I am aware of