Broken PD board terminal?

[Mk.32]

Originally Posted by EricVanWyk

As an inspector and the PD designer, I would be extremely hesitant to pass a PD with a repaired shank, for two reasons:

1) Safety. There is too much current in that connection for me to be comfortable with a rework. The shanks are force fit with enough pressure to cold-weld the square pins to the too-small round holes to better connect it to the >8 oz copper layers.

2) As a favor to the field crew, the CSA(s), and the team. It is extremely likely that a faulty repair here will randomly and briefly re-break and then re-attach, causing the robot to reboot and/or fail on the field. It simply isn't worth the risk.

That isn't to say that it is impossible to do correctly - I am just saying that it is a difficult high risk low reward rework.

Just wondering, why the 6mm threads and not just a 1/4-20?

I have seen a few teams break them because they try to use a 1/4-20 Nut on the shank. I am wondering if this is how this team broke it as well....