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Binding can result between plates if the plates are offset from one another, forcing the pin to bend as it snakes its way through the various plates Binding can also result if the plate spacing is incorrect as compared to the design values 38334 Calculations for Tilt-Pin Fixtures Modern fixture construction software should perform all of the necessary calculations automatically Yet it is valuable to understand the basic decision processes 383341 Minimum Hole Diameter Calculation The relationships between pin displacement, pin diameter, plate thickness, and drilled hole diameters are trigonometric We calculate Eq 38.

1: A = sin 1 (PD/PL) and HSmin = [SD/cos(A)] + [PT tan (A)] + HT where HSmin = minimum hole size in a particular fixture plate PT = fixture plate thickness SD = pin shaft diameter as it passes through the plate PL = overall pin length PD = horizontal displacement distance of the pin tail relative to the pin head location A = angle of pin tilt expressed as degrees from vertical (ie, a vertical pin has a tilt of 0 ) HT = minimum acceptable tolerance to ensure that the pin slides freely in the hole (381).

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The first term in the equation derives from the effective increase in shaft diameter in the horizontal plane as the pin tilts (see Fig. 38.10). The second term derives from the horizontal

distance that the center line of the pin travels as it passes through the plate thickness. The third term, as mentioned earlier, is to provide a minimal clearance. For angles of tilt below 15 , the value of the cosine is close to 1 (over 0.96), and for rough calculations the term may be omitted. (For a 20 mil diameter pin, the contribution of pin tilt to effective shaft diameter is less than 0.7 mil). Similarly, for the same small angles, the calculation of the tangent can be simplified to tan(A) PD/PL. The error incurred increases as the plate thickness increases. For a 0.1 in. thick plate, the error at 15 will again amount to something less than a 1 mil hole diameter. With these simplifications, for low tilt angles and thin plates, the formula may be reduced to that shown in Eq. 38.2, with an extra mil or two added to the clearance. HSmin SD + [PT (PD/PL)] + HT (38.2)

For the highest-accuracy applications, use the exact calculation. 38.3.3.4.2 Drill Bit Size Selection. Note that the minimum hole size calculated previously is often not the ideal drill size. The most common material used for grid fixtures is polycarbonate. Polycarbonate tends to have a finished hole size that is about 0.001 in. smaller than the drill size for plate thicknesses typically employed in fixtures. Therefore, 0.001 in. should be included in the tolerance figure HT to permit accurate drill bit selection. 38.3.3.4.3 Pin Lean and Pointing Accuracy. Pointing accuracy is defined as the pin s ability to hit an intended target, usually described as a radial dimension (the distance from the intended target to the actual contact location). Because the pin is typically not perfectly vertical, there are several possible sources of error, depending upon the type of pin employed.

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With the older headed pin types, the head sat above the top plate of the fixture. With modern headless approaches, the pin tip is usually flush with the upper surface of the top plate while in contact with the product. As the pin tip projects less (nearly zero) above the top plate surface, its tip position in x-y coordinates is better controlled by the hole in the top plate. For this reason, most modern fixture designs operate with the probe tips arriving flush with the top plate surface while the product and fixture are compressed. It is also preferable that the pins remain approximately flush when compression is released. If they project above the top plate surface, the tip moves out of position in x-y coordinates, as illustrated in Fig. 38.11. When a product is placed on such a pin, the tip initially contacts an incorrect target location. During compression, the pin must drag across the product surface as the pin retracts into the flush position.Thus some spring mechanism, which supports the fixture and pins above the array of grid spring probes, is commonly employed. The fixture may rest on a spring-loaded stripper plate over the grid of spring pins, or the fixture may be designed with spring feet on its underside. In some designs. the fixture kit itself is compressed.