The design of automotive relay PCB fast pins is a complex process that comprehensively considers many factors such as materials, structure, electrical, process and protection. Through refined design and strict quality control, the relay can maintain stable performance and long-term durability under high-frequency switching operation.
Silver alloy is selected as the contact material not only because of its high conductivity, but also because of its low contact resistance, good resistance to arc erosion and self-lubricating properties. These properties are particularly important in high-frequency switching operations because they help reduce wear and heat generated by frequent contact and separation, thereby extending the service life of the relay. Select high-performance PCB substrates, such as high-temperature resistant and low-expansion coefficient materials, such as enhanced versions of FR-4 (flame-retardant epoxy glass cloth laminate) or more advanced materials such as ceramic-filled PCBs. These materials can maintain stable dimensions and electrical properties in high temperature, high humidity and vibration environments, ensuring the accuracy and reliability of relay signals.
The pins are designed with thickening or special alloy materials to improve their mechanical strength and fatigue resistance. At the same time, the connection between the pin and the PCB may use a special welding process or mechanical locking structure to ensure that it will not loosen or break under high-frequency vibration. Considering the electromagnetic interference that may be generated by high-frequency switching, electromagnetic shielding structures such as metal shielding covers or specially laid ground layers are added during the design to reduce the impact on surrounding circuits. In addition to the basic heat sink design, advanced heat dissipation technologies such as heat pipes and thermal interface materials may also be used to ensure that the heat generated during high-frequency switching can be dissipated in time to prevent performance degradation or damage caused by excessive temperature.
The current peak is limited by circuit design to avoid excessive instantaneous current during high-frequency switching, thereby protecting the relay from damage. The integrated overload protection circuit automatically cuts off the circuit when abnormal current or voltage is detected to prevent the relay from being damaged due to overload. Filters are added to the signal path to reduce high-frequency noise and interference to ensure the purity and stability of the signal.
High-precision processing technologies such as laser cutting and precision machining are used to ensure the dimensional accuracy and surface quality of the pins and PCBs. Automated production lines are used for mass production to reduce human errors and improve production efficiency and consistency of product quality. During the production process, multiple and comprehensive quality inspections are carried out, such as appearance inspection, electrical performance test, environmental adaptability test, etc., to ensure that each relay meets the design requirements and quality standards.
In addition to dust and waterproof design, special environmental adaptability designs such as salt spray and mildew resistance may also be considered to meet the use requirements in different regions and climatic conditions. In the design and manufacturing process, the vibration and impact factors during car driving are fully considered, and shock pads, buffers and other measures are used to reduce the impact of vibration on the relay. Design structures that are easy to maintain and replace, such as pluggable pins, modular design, etc., so that quick repair or replacement can be carried out when necessary.