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The plug manufacturer had tried various methods of bending the pins but none were giving reliable and accurate results. Variations in the pin material, and the bending process itself, meant that, instead of the pin tails being parallel, they were out of alignment by several degrees making them unusable.

To achieve the desired result, each of the four pins, left, right, upper and lower, have to be bent in a different way. Slight variations in the material used to make up the different batches of pins require the bending process to be easily adjustable to accommodate different ‘springback’ characteristics.

The design and application engineers at William Hughes used their specialist knowledge of spring materials and production processes to provide an adaptable and accurate solution. This involved the design of a special machine that can work with the wire pins allowing adjustments to cater for the varying characteristics. Four interlinked machines are used to produce the pins in sets.

The machine specially designed by William Hughes ensures that each pin is positioned correctly before it is bent. As a further check for quality each movement of the four pins is checked electronically to ensure accuracy and consistency.

William Hughes has many years’ experience manufacturing a huge range of specialist formed wire products and springs to individual customer requirements. This includes compression springs, tension springs, wire forms, PCB test points and spring wire. Stringent quality checks to ISO 9001:2000, ISO/TS 16949:2002 or AS 9100, combined with the latest design, production and distribution techniques ensure continuity of supply, rapid delivery and competitive prices across the range.