Johoty’s Services of 6 Pin Connectors
Sample 6 pin connectors: engineers connect one-on-one. Design confirmation → DFM manufacturability review → high-speed CNC prototype machining → 100% functional and electrical integrity verification. The entire process of a single sampling is ≤2 weeks. The entire process is technically transparent, with no sales intermediaries involved.
Quality control: MIL and IEC dual standard full inspection. Contact resistance: <50mΩ, lifespan: ≥10,000 cycles. Temperature resistance range: -40℃~125℃, vibration resistance, and impact resistance tests comply with military and European standards. Each batch comes with a complete test report, and the core performance is fully traceable.
Delivery time: Standard sampling takes 14 working days, small batch engineering takes ≤14 working days for mass production delivery. The standard delivery time for mass production is 2-3 weeks (batch size<10K). ERP + MES system node control throughout the entire process, real-time reporting of customer production schedule progress.
MOQ for 6 pin connectors: There is no minimum order quantity limit for sampling. The minimum order quantity for a single project in the mass production stage is 3,000 pieces. Support multi specification verification requirements in the early stages of the project to avoid R&D cost backlog.
Logistics method: Efficient door-to-door guarantee throughout the entire chain. DHL/FedEx/UPS air freight standard delivery. Large scale projects can choose DDP sea freight and special customs clearance agents.
Qualification of liaison: The liaison should be an engineer with a design and development background in 6-pin connectors for more than 10 years. >10 years of experience in developing connectors for medical, aerospace, and industrial automation. Have complete process understanding ability. We can directly discuss tolerance zones, material stress, spring deformation, coating uniformity, and fatigue life issues..
Material control: Full traceability of aviation grade materials. The pogo pin is made of beryllium copper C17200/HBi grade, with a surface coating of ≥0.5μm hard gold. The consistency error of the insertion and extraction force is less than ±10gf. All material batches are accompanied by material analysis reports.
Long and stable service life: It has been in actual operation for over 48 months in aviation cockpits, medical endoscopes, and industrial servo control systems. On site feedback shows that the contact failure rate is less than 0.02%.
Customization ability: ability to exceed standard pitch and irregular structure. Pitch supports a range of 2.54mm to 12mm. Support irregular and spaced arrangement, multiple pogo pins mixed needle arrangement, and separate graphic design. Full coverage of electrical signal, high current, and mixed signal design capabilities. Compatible with high-speed signal integrity design (>5Gbps high-speed signal).
Confidentiality Agreement (NDA) and IPR: Sign complete NDA and IPR protection agreements with European and American medical, aerospace, and automation clients. All customer information, drawings, and technical specifications are strictly controlled and strictly prohibited from being leaked.
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Performance Test of 6 Pin Connectors
Contact resistance stability: The initial contact resistance is ≤ 50mΩ. After 10,000 full stroke insertions, the drift is controlled within the range of ±3mΩ. Meet the reliability requirements of high-frequency connections and conduct dynamic monitoring throughout the entire process according to IEC standards.
Plug and unplug life verification: The measured plug and unplug life is greater than 20,000 times. Complete continuous automatic insertion and extraction cycle testing under full load condition of 6-pin. The tolerance of the entire travel process control is ± 0.05mm, with high consistency and mechanical stability.
Consistency of holding force: Single pogo pin loaded with 0 to 1kg holding force test, with repeated measurement deviation less than 10gf. Long term stable contact pressure is strong to avoid contact fatigue degradation.
Vibration resistance performance: 10Hz to 2,000Hz broadband random vibration test, three-axis test lasting for 8 hours. The change in contact resistance after vibration is less than 1mΩ, and there is no instantaneous contact interruption.
Impact resistance: 50g acceleration, 11ms pulse impact test, 50 impact cycles. After testing, all pogo pins maintained electrical continuity without structural fatigue damage.
High and low temperature cycling test: 50 cycles of -40°C to 125°C. The single temperature rise and fall rate is 3℃/min, and the extreme temperature zone is maintained for 2 hours. After testing, the contact performance indicators remained within the initial deviation of 5%.
Moisture and heat resistance test: temperature 40°C, relative humidity 95%, continuous exposure test for 1,000 hours. After testing, the surface coating showed no bubbles, peeling, cracks, and no abnormal increase in contact resistance.
Current carrying capacity limit test: Under the condition of single pin 6mm stroke crimping, apply rated current 50A. After continuous power on for 4 hours, the temperature rise of pogo pin is less than 30°C. The test environment temperature is 25°C, and the air flow rate is less than 0.20m/s.
Signal integrity test: verified through high-speed signal integrity>5Gbps. Vector network analyzer test, insertion loss< -1.0dB@5GHz Time domain reflectometry (TDR) test shows a reflection coefficient of less than -20dB, which is consistent with high-speed signal integrity.
Uniformity testing of coating: 5μm hard gold coating, measured at multiple points using X-ray fluorescence spectroscopy thickness analyzer (XRF). The thickness uniformity is controlled within the range of ± 0.20μm. Effectively control the risk of long-term oxidation and wear failure.
Full traceability of reliability: All performance testing processes are regularly sampled and reviewed by third-party organizations such as SGS, Intertek, and CQC. The report number is bound to the batch number for archiving, supporting customers’ full cycle quality traceability needs.
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Customization of 6 Pin Connectors
Pitch size customization range:
Supports standard starting from 2.54mm. Customize the pitch spacing upwards with a tolerance control of ± 0.02mm. Suitable for high current isolation, high voltage insulation distance, and special mechanical layout requirements. We have covered customized aerospace servos, high current electric vehicles, and high-voltage pulse medical equipment.
Pin quantity and arrangement form:
Single row, multiple rows, and free arrangement of different spacing and shapes. On the basis of 6 pins, it supports extension to 48 pins. Customize multi row staggered arrangement, Z-shaped, L-shaped, and angled plug-in. The minimum spacing difference for staggered arrangement supports 0.3mm differential switching, and the electrical isolation meets UL and IEC specifications.
Customization of current carrying and signal composite:
Single pin maximum 50A, signal mixing support 5Gbps. Support high current and high-speed signal composite structure, with current pogo pin independent spring. Signal pogo pin fully shielded layout, bidirectional impedance matching optimization, mismatch jitter <2%. Servo servo control, autonomous driving control cabin, multiple composite interfaces for industrial robots.
Mechanical stroke and holding force customization:
Adjustable stroke from 0.8mm to 8mm. The minimum step size for stroke adjustment is 0.10mm, ensuring different lifetimes and contact pressure performance. The customized range of holding force for the entire journey is 30gf to 250gf. It has been applied to high mechanical strength interfaces such as medical endoscopes and vibration impact testing fixtures.
Tail end connection form:
Supports SMD surface mount, PTH direct insertion, crimping, flexible cable soldering, multi-layer PCB lamination. Full process DFM manufacturability verification. We can provide 3D files of assembly and fitting structures for customers to model and verify interface interference and thermal deformation allowance.
Material customization:
Core spring is made of C17200 beryllium copper, C17300 high conductivity copper, SUS304 stainless steel spring, or SWP-B. The surface coating supports Ni + Au double-layer plating, thick gold ≥0.5μm, and fine-tuned hard gold plating. The long-term stable operation of the ultra-low oxygen chamber has been verified, and the hydrogen ion corrosion resistance has reached ASTM B849-98.
Expansion of Insulation and Sealing Levels:
Customized IP67/IP68 Protection Levels. Multi-layer structure waterproof ring design and positive pressure sealing adhesive. We have completed a 2,000 hour long-term stability test of medical dialysis equipment under liquid conditions. The protective performance did not decrease after plugging and unplugging.
Customization capability for extreme high and low temperature environments:
-55°C to+150°C expansion design. All customizations are based on the application for thermal compensation spring design and thermal deformation verification. Satisfy extreme applications such as aerospace, polar drilling, laser light source systems, etc.
Development response cycle:
Complete the complete design manufacturability review (DFM, DFA, DFMEA) within 72 hours after receiving customer customized requirements. Support customers to quickly enter the process of structural simulation and interface interference verification.
Customized traceability and technical document delivery:
design drawings, material batches, process parameters, critical dimension CPK data. Full lifecycle FMEA risk points and process SPC fluctuation records. The entire electronic document is standardized and archived, and customers can specify the review process.
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FAQ
How many is the minimum safe electrical clearance between pogo pins?
For 6 pin connectors, >2.0mm is the effective air gap. According to IEC, when standard design is 2.54mm pitch, the actual effective air gap is ≥2.0mm. The creepage distance is ≥2.50mm, which meets the isolation requirements of most control applications. If higher voltage resistance design is required, it can be extended to a creepage distance of ≥ 6.40mm.
What is the permanent deformation control range of 6 pin connectors for springs under high insertion frequency?
Less than 5% travel offset, C17200 beryllium copper undergoes two-stage heat treatment, with a fatigue limit greater than 350 ksi. After 20,000 insertions, spring free travel attenuation is less than 5%. Maintain stable electrical contact pressure without accumulated displacement due to failure.
What is the maximum current that a single pogo pin of 6 pin connectors can carry?
Rated 50A, continuous full load temperature rise <30°C. Tested at 6.00mm pitch, under full pressure connection conditions, single pogo pin continuously flows 50A. Temperature rise is controlled within 30°C for 4 hours, with a test environment temperature of 25°C and natural wind environment. Design margin to cover automotive power, robot servo drive, and industrial power bus interface.
How does Johoty control the consistency range of coating thickness for 6 pin connectors?
Using X-ray fluorescence spectrometer for multi-point sampling detection, the uniformity deviation of 5μm coating thickness throughout the entire stroke is controlled within ± 0.2μm. The wear resistance stability is better than the 1,000 hour accelerated wear test, and the contact resistance drift is less than 1mΩ.
How long is development cycle for non-standard irregular interfaces of 6 pin connectors?
The complete set of DFX review data will be produced within 72 hours from the design confirmation. The customer has proposed limitations and application requirements for 6pin connectors. Engineers are required to provide complete validation reports for DFM, DFA, and DFMEA within 72 hours. Complete rapid prototyping within 14 days to ensure fast closed-loop validation of the front-end.
