From the name, you can know that the shape of the circular connector is cylindrical, and the connection surface is also circular. When the PCB circular connector is connected to the equipment, the waterproof function is very important.
If the environment where the connector is used is cold and humid, the socket of the connector can easily fail to work due to the harsh environment.
Circular electrical connectors can be divided into different levels. Generally, its level is distinguished by IP code, such as IPX, in which X represents the level. If the value of X is larger, the waterproof level is higher, which can be divided into 0 to 8 different levels.
2. The specific level data of the waterproof circular connector
When x=0: there is no protection against water.
When x=1: water droplets can be prevented from entering.
When x=2: when the inclination angle of the circular electrical connector is 16 degrees, water droplets will enter, but it is basically not affected.
When x=3: when the inclination angle of the connector is 65 degrees, the circular connector is sprayed by water, but the equipment is basically not affected and can be used normally.
When x=4: it does not matter even if all liquid is sprayed on the shell of the circular connector.
When x=5: tap water can be used to clean the prototype connector, and there is no damage to the equipment.
When x=6: the waterproof circular connector has a relatively strong waterproof capability.
When x=7: it can be immersed in water for a short time.
When x=8: it is suitable for continuous immersion and can avoid water entering the connector continuously.
The above are the eight waterproof levels of circular electrical connectors. You can choose the waterproof level according to the actual situation of use.
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Environmental parameters mainly include ambient temperature, humidity, sudden temperature changes, atmospheric pressure, and corrosive environment. The environment in which the aerospace connector is in use, storage, and transportation has a significant impact on its performance, so the corresponding aviation connector must be selected according to the actual environmental conditions.
1. Ambient temperature affects aerospace connectors
The metal material and the insulating material of the aerospace connector determine the working environment temperature of the connector. High temperature will destroy the raw materials, causing the insulation resistance and voltage resistance to decrease; for metals, high temperature can make the contact object lose its elasticity, accelerate oxidation and cause the deterioration of the coating. The usual ambient temperature is -55~100℃, which may be even higher in special occasions.
2. Humidity affects aerospace connectors
Relative humidity greater than 80% is the main cause of electrical breakdown. The humid environment causes the absorption and diffusion of water vapor on the surface of the insulator, which easily reduces the insulation resistance below MΩ. Long-term exposure to high humidity will cause physical deformation, decomposition, and overflow of the product, resulting in respiratory effects, electrolysis, corrosion, and crack.
Especially for aerospace connectors outside the equipment, environmental conditions such as humidity, water seepage and pollution are often considered. In this case, sealed connectors should be selected. For water-tight and dust-tight connectors, GB4208 shell protection grade is generally used to indicate.
3. Sudden changes in temperature affect aerospace connectors
Humidity sudden change test is to simulate the actual use of aerospace connector equipment in a cold environment to a warm environment, or to simulate a sudden change in the ambient temperature of a spacecraft or detector. Sudden changes in temperature may cause cracks or delamination of insulating materials.
At high altitudes where the air is thin, the plastic emits gas to contaminate the contact object, and the corona tends to increase, the voltage resistance performance decreases, and the circuit produces a short circuit fault. When the altitude reaches a certain value, the performance of the plastic deteriorates. Therefore, when using non-sealed aerospace connectors at high altitude, they must be derated.
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You will find a large number of popular military specifications military connectors, such as MIL-DTL-83513 miniature connector, MIL-DTL-38999 iii connector, MIL-DTL-32139 nanometer connector, MIL-DTL-26482 automotive connector, Arinc Connectors, etc., can be used for standard or custom-configured mil connectors. If you have any needs, please consult.
Aviation wire connectors are also referred to as aviation plugs because they are used in the military industry. They can be easily connected to power sources and can transmit signals at the same time. They are widely used in aviation, navigation, electric power and other fields. Correct use of it can ensure the reliability of the circuit and reduce the occurrence of accidents.2. The advantages of aircraft cable connectors
(1) If the electronic components of the equipment break down, they can be easily replaced.
(2) Besides the improvement of production technology, the use of aviation cable connectors can enable electronic products to be assembled more conveniently, and it also facilitates the mass production of electronic products and improves production efficiency.
(3) Nowadays, science and technology are developed. When we are installing aviation cable connectors, those new and perfect components can be replaced with old ones, which helps save cost.
(4) The flexibility of design has been greatly improved. Nowadays, when designing new products, engineers of aviation cable connectors can exert better flexibility in terms of the design and integration of products and the system composition of components.
Nowadays, as the structure of the avionics rf connectors becomes more enriched, many new structures are constantly being researched and discovered. In the future, its scope of use will become more extensive and it will boast more functions.
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The equipment allocation rate is the ratio of the actual number of parameters that can be tested to the number of parameters that should be tested specified in the product technical standards. For the quality consistency inspection of electrical connectors and their components, the equipment allocation rate should reach 100%.
2. Inspect the measuring range and resolution ratio of instruments and equipment
The measuring range and resolution ratio of the instrument and equipment shall be compatible with the test parameters specified in the items of product quality consistency inspection.
Suggestion: 1 / 5S ≤ a ≤ 2 / 3S I ≤ 1 / 5T – 1 / 10T
General Training Module:
S — the measuring range of the instrument
A — the checked value
I — the resolution ratio
T — the permissible error of tested parameters.
(1) 1/5S≤A≤2/3S
The value of the tested object is usually required to be within 20%-80% of the measuring range of pointer instruments and equipment such as spring scales, ergometers, torque meters, tension testers, ampere meters, voltmeters, insulation resistance detectors, etc. The detection accuracy and service life will be affected if the tested value is beyond the upper and lower limits of this range, .
The above factors have been considered in the design of electronic intelligent instruments. There is a certain safety margin between the upper limit of the range displayed by the instrument LCD and the upper limit of the range that the instrument can withstand, so users can use it at ease. For example, the upper limit of AC voltage set in the withstand voltage test of the 30X series multi-functional instrument produced by NAC company is 750V, and the AC voltage that the actual instrument can withstand is 1060V.
(2) I≤ 1/5T～ 1/10T
According to the test methods for electrical connectors in GJB1217, it is not allowed to exceed 1μs during vibration, impact, collision and cable pull-out force tests. According to the above provisions, the monitor with the detection sensitivity (resolution ratio) of 0.1μs should be selected. For example, the monitoring transient interruption time (0.1-99.9 μ s) and the detection sensitivity (resolution) of 0.1μs can be set on the NM-11A of NAC company according to the technical standards of the detected interconnection devices.
3. Check the accuracy of instruments and equipment
The accuracy of the instrument and equipment should be compatible with the permissible error range of the tested parameters. According to the different nature and characteristics of test tasks, enterprise test laboratories can be divided into inspection, monitoring and measurement. The measurement properties of the inspection and monitoring of electrical connectors and their components (wiring harness) can judge the product parameters or control the technological parameters within the permissible error range. The measuring error of the equipped instruments and equipment is required to be far less than the permissible error range of the tested (controlled) parameters, i.e. U < T. However, the measurement of unshaped design experimental articles is different from that of the first two categories. There is no specified range for the measured parameters, and only the accuracy (△ tolerance) is required for the measured parameters.
For the measured objects without technical standards or process documents, the actual measured values are usually provided to the commissioned surveyor only through the measurement. In this case, the requirements can be met as long as the limit error of measurement U is less than or equal to △ tolerance.
For example, the insulation resistance test, withstand voltage test and contact resistance test according to the connector product standard belong to the inspection category, while the control of process parameters such as the temperature and pressure during the insulator injection molding belong to the monitoring category. In the same way, the transient interruption time of dynamic environmental tests such as vibration and impact can be monitored by transient interruption monitors. The test of finalized products with product standard and permissible transient interruption time belongs to the inspection category, while the test of products that are not finalized and without product standard belongs to the measurement category when they are in design and process investigation tests.
The coming aging society in China has a strong demand for health care products. The explosive growth of the medical device market has brought unprecedented pressure and power to the component manufacturers currently used in life-saving technology. With the growth of the population aged 65 and above, the medical device manufacturing industry is growing. The demand to ensure people’s health is developing rapidly, and the demand of the medical market is also growing significantly.
The custom medical connector face many unique challenges. They must be able to withstand frequent connection and disconnection cycles, provide continuous and accurate performance guarantees in high-risk situations, and withstand frequent cleaning, sterilization and disinfection. It is also affected by rough treatment, shock and vibration, as well as extreme conditions in the high-pressure steam and pressure chamber.
The new generation of devices is using the growing Internet of things to improve connectivity. Devices designed for home use must be able to communicate with the expert medical team for diagnosis, and fixed imaging devices need to be able to quickly transfer information between departments or facilities.
Small portable devices, such as rotary dental tools for cleaning teeth, can easily be discarded in the clinic environment. The internal connector must ensure safe connection in case of vibration, collision and sudden impact. Larger devices, such as MRI machines, x-ray devices, and medical machines with wheelbarrows, can be squeezed into door frames and walls, or hit by patients’ wheel beds or cleaners. So, again, secure connectivity is the most important thing. In addition, disposable equipment, a rapidly growing medical equipment field, requires disposable connectors, which must find a balance between high performance and cost.
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There are many kinds of electronic connectors, but the manufacturing process is basically the same. According to engineer Hou from Joes Electronics, the manufacturing of connectors can be generally divided into four stages: stamping, electroplating, injection molding and assembly.
1. Stamping
The electrical plug manufacturing process produced by electronic connector manufacturers usually starts from stamping pins. The electronic connector (PIN) is made of thin metal strip by large high-speed stamping machine. One end of the large coil metal belt is fed into the front end of the stamping machine, and the other end passes through the hydraulic working table of the stamping machine and is wound into the tape feed roller. The metal belt is pulled out and by the tape feed roller rolled up, then the finished products are stamped out.
2. Electroplating
The connector pins shall be sent to the electroplating section after stamping. At this stage, the electronic contact surface of the military spec connector will be coated with various metal coatings. Similar to the stamping stage, problems such as pin distortion, breakage, or deformation will also occur when the stamped pins are fed into the electroplating equipment. Through the technology described in this paper, this kind of quality defects can be easily detected. However, for most machine vision system suppliers, many quality defects in electroplating process are still forbidden zones for detection systems. Custom connector manufacturers hope that the inspection system can detect various inconsistent defects such as fine scratches and pinholes on the electroplated surfaces of connector pins. These defects can be easily identified on other products (such as aluminum can bottoms or other relatively flat surfaces). Due to the irregular and angular surface design of most electronic connectors, it is difficult for the visual inspection system to obtain the images needed to identify these minor defects. Since some types of pins need to be coated with multiple layers of metal, manufacturers also hope that the detection system will be able to distinguish the various metal coatings in order to verify whether they are in place and in correct proportions. This is a very difficult task for vision systems using black-and-white cameras, because the image gray levels of different metal coatings are virtually the same. Although the camera of color vision system can successfully distinguish these different metal coatings, the problem of lighting difficulty still exists due to the irregular angle and the reflection effect of the coating surface.
3. Injection molding
The injection molding box base of the electronic connector is made in the injection molding stage. It is the usual process is to inject the molten plastic into the metal mold, and then form the base through rapid cooling. The so-called “omission” occurs when the molten plastic can not fully fill the mold, and it is a typical defect that needs to be detected in the injection molding stage. Other defects include the filling or partially clogging of the sockets (these sockets must be kept clean and unobstructed so that they can be correctly plugged into the pins in the final assembly). The machine vision system for quality inspection after injection molding is relatively simple and easy because the omission of box bases and the blocking of sockets can easily be identified using backlight.
4. Assembly
The final stage of electronic connector manufacturing is the assembly of finished products. There are two ways to connect the electroplated pin and the injection box base: single plug-in or combined plug-in. The single plug-in is to insert one pin at a time; the combined plug-in is to connect multiple pins with the box base at the same time. No matter which type of insertion is adopted, manufacturers require to inspect the omission and the correctness of positioning of all pins during the assembly stage; another kind of routine detection task is related to the spacing measurement of the connector matching surface. Just like the stamping stage, the military connector assembly also poses a challenge to the detection speed of the automatic detection system. Although most assembly lines detect one to two pieces per second, the visual system usually needs to complete several different detection items for each connector passing the camera, so the detection speed becomes an important system performance index again. After the assembly, the external dimensions of the connector on the order of magnitude is greater than the allowable dimensional tolerances of a single pin, which also poses another problem for visual detection systems. For example, some connector box bases are over a foot in size and have hundreds of pins, and detection precision of each pin position must be within one thousandths inch in size. Obviously, the detection of a one-foot-long connector cannot be completed in a single image, and the visual detection system can only detect the quality of a limited number of pins in a small field of vision at a time. There are two ways to complete the detection of the entire connector: Use multiple cameras (it will increase the system cost); or trigger the camera continuously when the connector passes in front of a lens, and the visual system stitches the single-frame images taken continuously together to judge the quality of the entire connector. The latter detection method is usually adopted by PPT visual detection system after the assembly of connectors.
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Crimp connection are mainly divided into two types: lathe crimp pins and stamped crimp pins.
When crimping the cable, there are some details to pay attention to during the stripping and plugging process.
When stripping the wire, ensure that the cutting edge of the insulation is smooth, the core is intact, and no insulation is left on the core. The wrong stripping will greatly reduce the connection effect.
Pay attention to the length and depth when inserting. If the cable is inserted too short, it may cause the termination to fail to reach the specified pulling force, because the metal-to-metal contact between the cable and the terminal is reduced; if the cable is inserted too far, the life of the mini crimp connectors is shortened. Taking bur crimping as an example, when the first window can observe the metal wire core and the second window can observe the cable sheath, it indicates that the position of the wire core is just right.
After the crimping is completed, if you want to comprehensively test the connection effect, you need to check the pull force and section.
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There are many connector companies, but we are one of the best choices for you.
From the perspective of the whole vehicle, we can see the trend of platformization and modularization of vehicles. For custom high voltage connector, there may be fewer and fewer connectors, but from an overall perspective, this is still a huge market.
1. Higher current
In the short term, because the voltage platform of the entire vehicle cannot be rapidly increased, as the cruising range increases and other requirements, the current increase is certain, which requires the power plug-in to withstand higher current.
Most of the current industry standards are based on the 8 mm terminal as the contact, which generally can only withstand the rated current of about 250A. How to increase the current and reduce the temperature rise, so as to maximize the use of the electrical conductivity of the cable, and reduce the square number of the cable is a key consideration for the custom connector manufacturer.
Of course, you can also try to consider associating the cooling system with the power plug-in circuit to achieve the goals of large current, small temperature rise, and lighter weight;
2. Data analysis, environmental simulation
The entire development of electric vehicles in the past 20 years has also accumulated more data for vehicles. These data will be very effective to help build a complete environmental model, which can effectively simulate and analyze the service life, safety hazards, and failure mechanisms of automobile parts and components.
Connector manufacturers have also accumulated a lot of practical application experience and database. By making better use of these actual data and performing mathematical simulation modeling, practical problems can be avoided more reasonably from the design side. At the same time, by making better use of digital construction environment models, the service life of the connector can be better simulated.
3. The connector of the future
As cars become more and more intelligent, the high voltage pcb connectors will never merely serve as an electrical connection point for transmission in future smart cars. This is very different from traditional cars. In the future, military style electrical connectors may become modular, and their functions will change with the changes in the application scenarios of the car parts;
At the same time, the emergence of intelligent driving will make the stability of the connection for transmission become a mandatory condition, and the reliability of electrical performance and other performance will be raised to a higher level;
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Connector: A bridge for transmitting signals between systems and modules.
1. Connector is the key component of electrical connection or signal transmission
Connectors are essential components for electrical connection or signal transmission between system or complete circuit units. Standard power connectors are a functional element that connects, disconnects, or converts a circuit or optical channel by means of electrical or optical signals and mechanical forces. It is used as an electrical or optical signal connection between devices, components, equipment, and systems. Transmit signals or electromagnetic energy, and keep the system from changing without signal distortion and energy loss.
Optoelectronic connectors are used wherever optical signal connections are required. As one of the basic components necessary for the electrical connection of circuit systems, they have been widely used in aviation, aerospace, military equipment, communications, computers, automobiles, industry, and household appliances. Has now become one of the pillar industries of electronic information basic products.
2. New trends in connector development: high frequency and high speed, wireless transmission, miniaturization, and intelligence
The large-scale use of high-performance military grade electrical connectors is the development trend of the future manufacturing industry. As a bridge for communication within the circuit system, the connector has the characteristics of easy maintenance and easy upgrade, meanwhile, it can simplify the assembly process of electronic products, improve the flexibility of design and production, thereby increasing the degree of automation of the entire system and reducing costs. Therefore, the performance of the connector will affect the operating efficiency and reliability of the entire system. In the future, the diversity, performance and quality of connector products will become important factors in the entire manufacturing upgrade and development process.
Custom industrial connectors are in great demand in more emerging areas. With the rapid development of 5G, Internet of Things, AI, and intelligent driving, the market has put forward new requirements for connector technology.
In communication equipment, connectors carry the task of data connection between terminals. The development of 5G will promote the growth of demand for wireless connectors. In automotive applications, with the continuous advancement of automotive intelligence, in addition to the original engine management system and other devices that require connector data connections, more advanced vehicle entertainment systems, intelligent driving systems, and other connectors have increasingly demanded connectors. Industrially, connectors require stronger reliability and performance. With the construction of the Industrial Internet, more reliable connectors are needed between industrial equipment and networks.
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The market for various high-end electronic products is growing rapidly, and the global production capacity of connectors is continuously shifting to Asia and China, so Asia has become the most promising place for connector development (pin header and female header), and China will become the fastest-growing and the largest connector market in the world. It is estimated that the growth rate of China’s connector market will continue to exceed the global average level in the future. In the next five years, the annual growth rate of China’s connector market will reach 15%. By 2010, China’s connector market capacity will reach 25.7 billion yuan.
The technological innovation of connectors
The main types of military power connectors are FPC connectors and SATA connectors. The supporting fields of the connectors include transportation, communication, network, IT, medical care, home appliances, etc. The rapid development of the product technical level in the supporting fields and the rapid growth of the market strongly drive the development of connector technology. So far, connectors have developed into serialization and specialization products with complete product categories, rich variety specifications, diverse structure types, professional direction subdivisions, obvious industry characteristics and standard system specifications.
Generally, the development of connector technology shows the following characteristics: high speed and digitization of signal transmission, the integration of all kinds of signal transmission, the miniaturization and micromation of product volume, low cost of products, the surface-mount terminating of contact parts, the combination of modules, the convenience of plug and plug, etc. The above technologies represent the development direction of connector technology, but it should be noted that the above technologies are not necessary for all connectors. Connectors in different supporting fields and different using environments have completely different demand points for the above technologies.
At present, the functions of electronic products are becoming more and more powerful and comprehensive, which puts forward higher and more diversified demands for connectors. For example, the transmission rate of electronic devices is getting higher and higher, and in order to meet the transmission and exchange of large traffic data, the requirements of high-speed transmission and digital transmission are put forward for connectors. However, more and more signals such as microwave signal, optical signal, high voltage signal and power signal are needed to be integrated into the same connector to save the space of the equipment and reduce the size of the equipment. Meanwhile, signals are required to be transmitted independently without interference, which determines that the development trend of connector signal transmission integration will be more and more obvious.
The market demand for the centralization and miniaturization of connectors has promoted the innovation in terminal technology. Semiconductor chip technology is becoming the technical driving force for the connector development at all levels of interconnection. For example, with the rapid development from the chip packaging of 0.5 mm spacing to the chip packaging of 0.25 mm spacing, the pin number of class I interconnect devices (inside IC devices) and class II interconnect devices (the interconnection of device and board) ranges from hundreds of lines to thousands of lines. Press-fit contact technology is widely used in cylindrical slotted sockets, elastic strand pins and hyperboloid spring socket connectors, which greatly improves the reliability of the connector and ensures the high fidelity of signal transmission.
Terminal technology enables connectors to constitute a new connector product, the push-in connector, which is primarily used for system-level interconnection. The biggest advantages are that it does not need cables, is easy to install and disassemble, and is convenient to replace on site. In addition, the insertion speed is fast, the separation is smooth and stable, and high frequency response can be obtained, which is suitable for spacecrafts. The military connector assembly technology is developing from plug-in installation technology to surface-mount technology, and the development trend is towards micro-assembly technology in the future. The adoption of MEMS (micro electro mechanical system) will be the power to improve the connector technology and cost performance.
Application fields of pin headers and female headers
Now pin headers and female headers are applied to more and more fields and industries. What are the main application fields of pin headers and female headers? Here are the details about the answer.
Although pin headers and female headers have the standard of hot plugs, the current pin headers are mostly designed for HDD, and the maximum plugging and pulling time is only about 200 times. If the plugging and pulling time is beyond the limit, the pin PCB connector will deteriorate and the hard disk may even be damaged. The plugging and pulling time of pin headers used for external applications is only about 2,500 times.
Driven by technological progress and cost reduction of pin headers and female headers, the technological strength and industrial position of pin headers will determine the development speed of related enterprises in China, because the emergence of new technology requires electronic enterprises to keep pace with the progress of technologies, and the position of the industry also determines the position of enterprises in the upstream and downstream price negotiations.
In large and medium-sized cities, flat-panel TV has entered the substantive popularization stage, but facing the complex prices, sizes and pin headers, the complicated technological functions and the mixture of high-end and low-end products, many consumers feel confused. Improving the production process of pin headers and female headers not only simplifies the assembly process of electronic products, but also simplifies the mass production process and the maintenance. In case of the failure of an electronic component, the failure component can be replaced quickly for upgrading when it is equipped with pin headers and female headers. With the progress of technology, the component can be updated when equipped with pin headers.
In recent years, the market demand for pin headers and female headers has maintained a high growth rate. The emergence of new materials and new technologies has also greatly promoted the improvement of industrial application level. At present, the development trend of the pin header and female header market is getting better and better, and pin headers and female headers can realize their own value in different fields.
In view of the improvement of miniaturization and intelligence level of pin header and female header technology, it is an inevitable trend to integrate multiple functions on the basis of information acquisition, and the data fusion technology of multiple pin header and female headers also promotes the development of this technology. The integration of local data resources provided by multiple pin headers and female headers of various or different classes that are distributed in different locations and the adoption of computer technology analysis can eliminate the redundancy and contradiction between the information, provide complementary functions, reduce information uncertainty and obtain the consistent interpretation and description of the tested object, so as to improve the rapidity and correctness of the decision-making, planning and response of the system, and make the system obtain more adequate information. The information fusion occurs at different information levels, including data layer fusion, image feature layer fusion and decision-making level fusion.
Compared with single pin header and female header, the information of micro pin header and female headers has the following advantages: fault tolerance, complementarity, instantaneity and economical efficiency. Therefore, multiple pin headers and female headers are promoted and applied gradually. In addition to military applications, they have been applied to automation technology, robotics, marine surveillance, seismic observation, construction, air traffic control, medical diagnosis, remote sensing technology and other aspects.
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