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a Crimping a wide flat into the pin, and trapping the oversize flat between two plates b Trapping the pin in a sheet of foam rubber such that friction retains the pins c Passing the pin through a sheet of spandex cloth that grips the pin d Passing the pin through a sheet of drilled latex rubber that grips the pin with flexible flaps 38336 Examples of Real-World Fixture Designs While many combinations of fixture techniques have been employed, it is worthwhile to compare several popular examples No substantial discussion of older headed rigid pin types is included here, as their use is largely disappearing Most fixtures today are built with headless pins that compress flush into the fixture without bottoming on the spring probe below, such that the contact force is entirely controlled by the spring (excluding friction or binding effects) Figure 38.

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14a represents a common bent or curved pin design using 375 in music wire pins The upper and lower fixture plates are held apart by a spring mounting, and the entire fixture compresses during actuation The pins hit the intended target perpendicularly, because they bend toward vertical as they reach the product area But extra force is required, increasing pad marking Hole diameter in the top plate can be tightened to improve pointing accuracy because all pins pass through perpendicularly, and a fairly thick top plate is possible For a given pin length, the maximum possible horizontal displacement is more limited than in straight pin designs, because all displacement must occur in the lower portion of the pin length The hanging middle plates do not contribute to torsional stability of the fixture design, increasing distortion under compression.

This in turn can increase pin binding as the pins try to bend and slide through the compressing fixture envelope The pins usually used have a flattened crimp trapped between the upper two plates and must be loaded or serviced with the upper plate removed Pin loading is therefore difficult The increased diameter in the crimp region limits close spacing of the probe Finally, the crimp cannot be employed on very finediameter pins, as they would weaken excessively..

Figure 3814b illustrates a significant evolution from Fig 3814a Here the pins are not bent or curved Shorter pins (3 in) are sometimes used, providing about the same horizontal translation as in Fig 3814a Deleting the bend significantly reduces pin binding A retention crimp similar to the previous example is used, relocated toward the bottom of the fixture where the pins are more widely spaced Pins are loaded from the bottom side, with the lower plate removed This design still requires disassembly of plates for pin servicing, but the bottom plate is somewhat easier to reinstall due to the possibility of larger hole sizes Fixtures are usually rigid as opposed to spring-loaded, reducing friction effects during compression Variations of the fixtures illustrated in Figs 3814a and 3814b are produced using a foamrubber pin retention method.

In these versions, the crimp on the pin is deleted and a sheet of foam rubber material is sandwiched between the two lower plates During loading, pins are forced through this foam, and friction holds them in place This provides the important advantage that individual pins can be replaced without fixture disassembly Unfortunately, highdensity zones incorporating many pins stretch the foam rubber material The stretched foam holds adjacent pins so tightly that a group of pins becomes reluctant to move except as an almost solid block The resulting pin binding effect causes contact reliability and product marking problems Also, the foam tends to deteriorate with time and/or heavy use As densities have increased, this fixture has become difficult to use Figure 3814c illustrates a retention technique employing a very thin sheet of drilled Mylar combined with a unique feature on the pin.