Interesting manufacturing conundrum - Page 1
Forum section: electronics / projects

author: Dago
author_rank: Frequent Contributor
timestamp: June 26, 2015, 11:42:34 am
content: I've run to an interesting problem at work. We have some 3U servers that we would like to fit with large GPUs. The card fits but the extra power cable does not fit (points upwards towards the case "roof"). There is around maybe 3-4mm of space above the power connector.Using 4U rack cases for the servers is not an option (due to space constraints) and using smaller GPUs is not an option either (due to computing power requirements).I made the attached low-profile power connector that has low enough profile and make the power cables to point sideways. The only problem is that it is totally and utterly not manufacturable in any quantity. I used crimp pins which I trimmed and re-formed a bit with pliers which I then soldered to a PCB. The main issue is that there is no easy way to position the pins and the pins also very easily suck in all the solder. Also tried using the mating connector as a guide for the pins etc. but I just ended up soldering the halves together. I'm also not too convinced this solution will last too long because there is nothing else supporting the pins except the solder. So you probably don't have to twist the connector too much before the pins will break off.The quantity is not humongous, we'd need maybe couple hundred of these or so. The good thing is that they are very price insensitive. They could probably cost 100€ each and it wouldn't really make a difference. I really don't have too many good ideas how to make these.Some ideas I've had:1. Make some kind of soldering jig from teflon or something which has (steel?) pins which prevent the crimp connectors from sucking in the solder, then solder them (in this quantity by hand is enough). Maybe design some type of supporting plastic connector body too (and 3D print it?)2. Make the pins by 3D printing (laser sintering) from some solderable material and then solder them with some jig (mating connector maybe)All fairly involved/complex. We don't have any mechanical designers or CAD tools etc. so it gets a bit complicated pretty fast.Any clever ideas?

author: RogerRowland
author_rank: Regular Contributor
timestamp: June 26, 2015, 11:58:32 am
content: Maybe I'm reading the problem slightly wrong, and my 3D spatial awareness is shot to bits right now, but just in case it's not total bull, it's nothing like this you need is it?http://www.moddiy.com/products/6%252dPin-Graphics-Card-PCIe-Male-Header-Connector-%252d-90%25-Angled-%252d-Black.html

author: PA0PBZ
author_rank: Super Contributor
timestamp: June 26, 2015, 11:59:07 am
content: Would this work?http://www.ebay.co.uk/itm/Sleeved-PCI-E-6-pin-90-degree-left-power-extender-w-low-profileALL-BLK-USA-MADE-/261567563062

author: daqq
author_rank: Super Contributor
timestamp: June 26, 2015, 12:38:46 pm
content: You can use SMD spring pins and use some clever mechanical solution to press them into the connector - not the most graceful of solutions... or some creative (read: horrible, unholy hack) use of spring finger contacts.

author: amyk
author_rank: Super Contributor
timestamp: June 26, 2015, 12:51:44 pm
content: In other words, what you're looking for is a PCIe 6pos board-mountfemale?How about these?http://www.molex.com/molex/products/listview.jsp?query=&offset=0&filter=&fs=categoryid%3Apcbreceptacles%2Cproductname%3A%22mini-fit+bmi.%22%2Capplication%3Aboard-to-board&npp=20&sType=z&autoNav=1&path=cPCBRECEPTACLES%23%230%23%2311%7E%7Enf214%7C%7C36&channel=ProductsGold and less flammable ones cost more. The tin, slow-burning ones are the cheapest:http://www.digikey.com/product-detail/en/0015247063/WM17730-ND/1633793

author: Dago
author_rank: Frequent Contributor
timestamp: June 26, 2015, 01:31:13 pm
content: Quote from: amyk on June 26, 2015, 12:51:44 pmThose are exactly what I want! I am absolutely sure I went through Molex selection and couldn't find any female connectors that were not crimpable. Or maybe I was looking at locking version or something. But I guess I'm just blind! But thanks a lot, this solves my problem!PA0PBZ: I ran in to that one before but the mating connector edge stops at the "lip" of the connector so there is still quite a lot of height, would have still been too high.

author: amyk
author_rank: Super Contributor
timestamp: June 26, 2015, 02:45:21 pm
content: You should make sure the keying is right...http://www.frozencpu.com/images/products/large/ele-154_3.jpg