From Design Innovation to Performance Excellence: A Comprehensive Upgrade of Connector Products
In response to common problems in the connector market, such as loose structure, inefficient assembly, and inconsistent electrical performance, Adam's engineering team systematically upgraded their flagship connector products.
Old version
The old version of the product has revealed structural weaknesses during long-term use: the fixing screws and hexagonal nuts cannot be effectively pre-installed on the plastic shell, which not only increases the assembly time on the production line, but also poses a risk of falling off; after the upper and lower shells are closed, due to the short buckle design, there is a significant swing gap of 0.5-0.6mm, which affects the overall firmness and service life.
New Product Improvements
1. Integrated Design: The fixing screws and hexagonal nuts can be directly and reliably secured to the plastic housing, eliminating parts scattering during transportation and handling, significantly reducing labor costs and error rates.
2. Reinforced Engagement Structure: The redesigned engagement points and housing fit structure eliminate lateral swaying after assembly of the upper and lower housings, ensuring the long-term structural integrity of the connector under vibration.
3.Improved Reliability: By eliminating unnecessary parts such as iron washers, the Bill of Materials (BOM) is further simplified while maintaining performance, reducing the complexity of supply chain management and assembly processes.
4.Verification Data: We conducted a rigorous drop test on the semi-finished product. After being dropped vertically from a height of 70 cm, neither the screws nor nuts shifted or came loose, demonstrating the superior reliability of the new structure under accidental impact.
Project Outcome
This upgrade involved systematic improvements to structure, processes, and core electrical performance, demonstrating our expertise in solving real-world problems through design and providing customers with highly reliable connection solutions.
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