DMAC Electrical Contacts Coach User Guide

1. What this app does

DMAC Electrical Contacts Coach helps you organize electrical contacts design work, root-cause investigations, product testing, and team collaboration. It is designed for connector, switch, relay, crimp, compression, bolted-joint, power-connection, and high-speed interconnect work.

2. First login

• Open `http://localhost:9080`.
• Use Create Account to make your own account, or log in as the local admin.
• The default admin email is `admin@dmac.local`.
• The default admin password is `ChangeMeNow!123`.
• Reset the default admin password immediately.

3. Light mode and dark mode

Use the Theme button in the top navigation. The theme control appears on every page. The app stores your choice in your browser.

4. Create users

Admins and design leaders can open Admin and create users by entering name, email, role, engineering discipline, and a temporary password. The new user will be asked to reset the temporary password after logging in.

5. Create teams

Open Teams and create a team for a design project or root-cause investigation. Choose a lead discipline such as Electrical Contacts, Mechanical Engineering, Materials Science, Tribology, Product Test, or Quality Assurance. After creating the team, open the team detail page and add or remove members.

6. Create projects

Open Projects and create a project. A project can be personal or assigned to a team. Use the project page to record contact type, rated current and voltage, normal force, expected cycles, materials and plating, environment, suspected failure mode, root-cause hypothesis, test plan, mitigation plan, and QA gate.

Click **Save Design Features** after editing.

7. Run project review

On a project page, click **Run Project Review**. The app estimates constriction resistance, voltage drop, I2R power, contact spot temperature, overall screening risk, leading mechanisms, and recommended next tests. This result is saved to the project and logged as a coach run.

8. Use case studies

Open Case Studies. You can filter by Easy, Intermediate, Challenging, industry, and keyword. Open a case to read the scenario, suspected mechanisms, tests, and corrective actions. Click **Save As Project** to turn a case into your own editable project.

9. Use the Coach page

Open Coach to run a standalone screening simulation. Enter the current, force, cycles, material stack, environment, humidity, temperature, and contact radius. Click **Run Simulation** to see the screening result.

10. Knowledge Hub

Open Knowledge to review the app's main technical themes: definitions, formulas, fretting corrosion, constriction resistance, contact temperature, crimp/compression connectors, electroplates, high-frequency effects, arcing, test methods, materials selection, and RCA workflow. Use the formulas for early screening only. Final designs still require qualified engineering review and product-specific testing.

11. Implemented Engineering Tools

Open **Tools** after logging in. The former premium roadmap has been converted into working app features:

• **Copilot:** asks local approved-source electrical contacts questions and gives source-topic references.
• **Calculators:** computes constriction resistance, voltage drop, I2R heating, contact spot temperature, skin depth, Hertz contact radius, and Arrhenius acceleration factor.
• **Design Rules:** runs pass/warn/fail checks for a selected project and product family.
• **Materials:** ranks material and plating options for your current, cycles, environment, signal level, and cost priority.
• **Test Data:** lets you paste CSV test/logger data, compute numeric summaries, flag trends, and save the dataset to a project.
• **RCA Board:** lets you add evidence cards using fishbone and 5-Why categories.
• **Requirements:** maps project requirements to pass/warn/fail status and evidence notes.
• **Approvals:** captures multi-disciplinary approval status and comments.
• **Reports:** creates a downloadable Markdown report from project design data, coach runs, evidence, requirements, approvals, and test datasets.
• **Academy:** provides short learning modules and a quick quiz.
• **Integrations:** exports a project package as JSON for downstream tools or private repositories.
• **License Center:** lets admin/design leaders enter local license, trial, seat, Wix, Stripe, Postmark, and Cloudflare Tunnel settings.

12. Recommended workflow

• Create or select the project.
• Build the team.
• Enter design features.
• Run project review.
• Use Design Rules and Calculators to screen margins.
• Use Materials to review candidate plating/material systems.
• Paste test data when lab results become available.
• Add evidence cards during RCA work.
• Map requirements and collect approvals.
• Generate a report and export the project package.
• Duplicate the project when you want a Save As copy.

13. Important disclaimer

The app provides screening, organization, and education. It does not replace product-specific testing, certified safety review, standards compliance, or qualified engineering judgment.