Aircraft Connector/UAV Connector

Modern military and commercial aircraft use a large number of electrical and electronic systems to monitor and fly the aircraft, manage the engine, provide communication, etc. at the same time, coupled with some entertainment equipment, the installation of these systems means that each aircraft needs hundreds or even thousands of aircraft electrical cables and connectors and uav connectors.

As we all know, manufacturers in the aerospace field have the highest requirements for the electrical and electronic interconnection industry. As with the military, the selection and use of aerospace connectors are greatly influenced by standards and approvals, overall performance and weight, and space savings.

The location and application determine the requirements to be met by the aircraft electrical connectors/aircraft electrical terminals. These requirements include dielectric withstand voltage, operating temperature, insulation resistance and electromagnetic interference resistance, vibration / shock, flammability and smoke / toxicity, etc. Generally, the most important requirement for airborne electronic connector is to be able to handle shock, vibration, general durability and temperature cycle.

Application Of UAV/Aircraft Cable Quick Connectors

Sunkye EMI filtered connector is designed to meet stringent aerospace performance requirements. Each aircraft electrical connectors series is offered with standard low-pass Pi or C filter arrays, or with customized filters to meet specific frequency and capacitance requirements. Thermally conductive epoxy protects the filter package from mechanical and heat stress and also provides a waterproof seal. All filtered receptacles are intermateable with standard plugs and connector savers, and each respective family of connectors is supplied with a range of shell styles in both environmental and hermetic configurations.

Advantages Of Rectangular Aircraft Connectors/UAV Connectors

Rectangular connectors can stack multiple connectors, so they can provide higher contact density. This is a big advantage if the space is limited and the I / O count is high. At the same time, connection and wiring density are also very important size considerations.

Why Choose Sunkye As Your Aircraft Connectors/UAV Connectors Supplier

An aircraft or UAV connector is worth mentioning that because of the increasing frequency and data transmission requirements of commercial aircraft, the aircraft electrical connectors of commercial aircraft need multi-function to meet different applications. Includes insertion options for signal, power, RF, and fiber terminals, as well as hybrid insertion that can include all of these options.

For the aircraft electrical cable connectors applied in the fuselage, higher data transmission rate and the distance that data must pass are also critical. Some solutions need to design the signal integrity of the whole cable components and connectors, and select the solid and reliable connectors that meet the requirements of data rate and EMI shielding.

For high-speed data links (copper optics, fiber optics) are increasing. If the aircraft power connectors can adapt to the high speed, but still can not make the terminal too cumbersome, it can meet the needs of more customers.

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Aerospace Electrical Connectors

Space rated connectors are almost everywhere in military and aerospace applications. As the interconnection of transmission signal and power, aerospace D sub space grade connectors must meet the requirements of strict outgassing and residual magnetism test to be suitable for aerospace applications.

Ground to satellite communication is a massively challenging undertaking. People need data fast, with high signal integrity, to quickly assess the message and make decisions. A poor or delayed signal may lead to a wrong conclusion or missed opportunity.

Space grade connectors have standards of MIL-C-5015, MIL-C-26482, MIL-DTL-38999, MIL-DTL-55302, MIL-DTL-83513, MIL-DTL-32139.

Application Of Aerospace Electrical Connectors

Connectors are an important basic component that is almost ubiquitous in military and aerospace aircraft & aerospace applications and serves as interconnects for transmission signals and power, which has to meet stringent testing for outgassing and residual magnetism to be suitable for use in airspace & aerospace applications , meanwhile, match for system requiresment of anti-irradiation, high-performance vacuum outgassing, adapt to ultra-high temperature and ultra-low temperature extreme environment, non-magnetic, prevent harmful gas intrusion, anti-condensation, vacuum cold welding technology. Sunkye, one of the most experienced aerospace connector manufacturers, can provide you all kind of aerospace power connectors you need according to your requirements.

Three Basic Types Of Aircraft D Sub Connectors Classified From A Technical Point Of View

① According to the connection modes of aircraft d sub connectors: there are threaded connection, bayonet (quick) connection, bayonet lock connection, push-pull connection and direct plug connection;

② According to the shape: aircraft D sub connectors can be circular and rectangular (cross section);

③ According to the working frequency: aircraft D sub connectors have operation types of low frequency and high frequency (with 3MHz as the boundary);

Three Types Of Technical Parameters Of Aerospace Electrical Connectors

① Electrical performance: rated voltage, rated current, contact resistance, withstand voltage and insulation resistance, shielding, RF anti-interference attenuation value;

② Mechanical properties: number of contact pairs and pinhole, installation mode and shape, shell material, insulator, contact, mechanical life, etc.

③ Environmental technical performance: working temperature, working height, vibration, impact, constant acceleration, leakproofness, salt fog, moisture and mould resistance, etc.

Among all the aerospace connector manufacturers, Sunkye can be the one you are looking for.

FAQ OF AEROSPACE ELECTRICAL CONNECTORS

Q.What are the measures to ensure the reliability of space grade connectors?

A.Select the space grade connectors listed in the list of qualified products published by the military components’ management center of the national defense science and engineering commission. Carry out delivery test and secondary supplementary screening.

Q.What are the factors that determine the storage reliability of space grade connectors?

A.The temperature, humidity, cleanliness and corrosive gas of the storage environment will affect the performance parameters of the space grade connectors, especially the humidity is particularly sensitive to the insulation resistance.

Q.How to ensure the installation reliability of aerospace electrical connectors?

1. The installation personnel shall first understand the technical characteristics of the electrical connector, and shall not use it under overload or overstress, and shall correctly connect and separate it according to the operation and use methods to avoid burning or damaging the electrical connector.

Now the price of military spec electrical connectors is low, if you are interested, please leave us a message.

For some industries, the waterproof connector is very necessary, so that it can protect the safety of the product, and it is also a guarantee for personal safety.

How to prefabricate cables for waterproof d connectors?

XLPE insulated cables above 110kV level mainly use metal sheath to make the cables meet the waterproof requirements. The biggest feature of the metal sheath is that it is completely impermeable, so the cable with a metal sheath has very good radial water resistance. The main types of metal sheath are: hot-pressed aluminum sleeve, hot-pressed lead sleeve, welded wrinkled aluminum sleeve, welded wrinkled steel sleeve, cold drawn metal sleeve, etc.

The power cable can provide the input power for the waterproof connector system. This power supply uses the traditional wiring method, or a standard waterproof plug is installed on the power supply end, and a required socket connector can be prefabricated on the other side.

The extension cable needs to be installed with an inner socket or plug at the end of the relevant cable, and the wiring cable needs to be equipped with a plug and a bare wire end for the waterproof plug to connect the final device.

Breakout connector: The waterproof plug can be pre-installed on site to provide direct wiring for electrical user devices. All waterproof connectors marine are delivered with a stress-reduced housing and are compatible with all common types of cables. According to the requirements, the waterproof plug has a spring or screw connection technology.

Sunkye is a professional ip68 waterproof cable feedthrough connector manufacturer and supplier, who support custom military connectors china for a complete range of high-performance applications. A wide variety of military connector options are available to you, feel free to contact us.

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1. Introduction

The reliability of RF high frequency connectors is a very important problem in the whole machine or the system use, because as a component, the reliability of the RF connector directly affects or determines the reliability of the whole machine or the system. The reliability of RF connectors is related to their structural design, production process, production technology, selected materials, quality control and their correct application. The structural design is the most important among these factors, which plays a decisive role in the inherent reliability of the product. Therefore, in every stage of development and design or in the reliability growth test, special attention should be paid to how to improve and ensure the inherent reliability and the use reliability of the product.

With the passage of time and the continuous development of science and technology, the design theory and measurement technology are constantly updated and improved through the test of practice and the accumulation of experience, and the defects and limitations in the early designs are gradually exposed. Therefore, it is necessary to adopt new concepts, new technologies and new materials to improve the old products and old structures, and take measures to improve the inherent reliability of products.

2. Measures

2.1 Reinforcement method

Aiming at the outer conductor of the RF connector or the parts of the inner conductor where contact failure is prone to occur, the reinforcement method is to add stiffeners and cut no grooves or narrow grooves to improve the rigidity and mechanical strength of the failure parts and improve their contact reliability and mechanical life without affecting the electrical characteristics (e.g., VSWR, insertion loss) of RF connectors.

Case 1: In the vibration test and the mechanical life test of the Q9 RF connector( an obsoleted type) and the early BNC RF connector, the distortion and flying flake phenomenon often occur at the elastic grooves of the outer conductor end face, which results in the increase of the contact resistance of the outer conductor and the failure. Aiming at this type of failure, reinforcement measures should be taken, that is, reinforcement bars should be added at the end of the connectors such as the BNC RF connectors specified in the current IEC168-8 standard.

2.2 Calibration method

Calibration or alignment method is to shorten the insertion length of pins and extend the axial length of threads in the interface structure design of some micro RF connectors. During the connection process of connectors, this method can make the connector plug contact with the socket first, and alignment the pin and the jack in a straight line before contacting and connecting, so as to prevent the pin from damaging the jack in the connection process, resulting in the failure.

For example, the jack damage shown in Figure 7 is prone to occur in the connection process of SMA connector and APC-3.5 connector. After using the calibration method, the failure caused by the jack damage can be effectively avoided in the connection process of the connectors such as 2.92mm, K, and 1.85mm connectors.

2.3 Balance method

The balance method refers to the structure design of high frequency contacts in high and low frequency hybrid connectors. The adoption of the balance method should meet the requirements of electrical characteristics (such as RVSW) within the applicable frequency range and consider the overall mechanical life of high and low frequency hybrid connectors. The jacks of the inner conductor system should be strengthened and the inherent reliability of high-frequency contacts should be improved as much as possible.

2.4 Coating lubrication method

The coating lubrication method means applying the coating agent or lubricant on the surface of the contact parts of RF connectors to improve the corrosion resistance and wear resistance of the contact parts, so as to improve the contact reliability and mechanical life.

Gold is the most difficult to corrode and tin is the easiest to corrode according to the degree of electrochemical corrosion of gold, silver and tin, but it is quite the opposite that the gold-plated contact is corroded most, while the tin coating is corroded less from the actual use of electroplating contacts. This is because as a precious metal, gold tends to be thin, while tin, as a base metal, is thicker. In the case of general plating quality, the relation curve between the thickness of the coating and the number of pinholes is shown in Figure 9. Thin coatings with more pinholes are easy to be corroded; thick coatings are difficult to be corroded.

2.5 Optimum seeking method

The optimum seeking method refers to choosing the suitable connection mechanism optimally according to use characteristics in the design of the connection mechanism of RF connectors or in the selection of connectors to avoid the contact failure caused by the improper selection of the connection mechanism, so as to improve the use reliability.

The common connecting mechanisms of RF connectors are shown in Table 1. Different connecting mechanisms have different applicable conditions and characteristics, so the applicable connecting mechanism should be selected according to the characteristics of use.

3. Conclusion

Some of the measures and examples listed above have been reflected in the standard interface structures of the products, and in some cases, the two structures coexist in the same product type. As measures to enhance the inherent reliability of products, the methods listed above are not only or unique. Designers can carry out specific analysis according to the contact failure forms   occurring in product contacts and adopt methods that are different from the above measures to improve the use reliability. They can also apply one or some of the above measures jointly to improve the use reliability. It is unnecessary to change the structure when the existing structure can meet the use requirements.

The methods above aim at different failure forms, and they can be used as a reference for designers to design products initially. In addition, the methods can be clues in analyzing connector failures and searching for failure causes, and they can also be adopted in reliability growth tests.

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In the field of connectors, FFC connectors and EMI shielded FPC connectors are often confused. Although both are flexible cable connectors, there is a certain degree of difference between FFC connectors and FPC connectors.

Flexible flatcable connector, FPC is a flexible print circuit. In terms of the manufacturing of the two, the way their lines are formed is different.

FPC is a flexible circuit board with different single-sided, double-sided and multilayer structures after FCCL (flexible copper clad foil) is processed by chemical etching. In FFC, a flat copper foil is sandwiched between the upper and lower insulation foil films.

The FFC connector is a new type of data cable made of PET insulation material and extremely thin tinned flat copper wire, which is laminated through the production line of high-tech automated equipment. It has soft, free bending and folding, thin thickness, small size, and connection Simple, easy to disassemble, easy to solve electromagnetic shielding (EMI).

Strictly speaking, FFC is naturally much cheaper. Considering the production cost, more companies prefer to use FFC related designs.

Sunkye is a reliable connector manufacturer who provides professional FFC connectors and FPC connectors, contact us and get more info now.

We can provide different sorts of military socket for sale, if you have needs, please contact us.

For the connector industry practitioners, military rf connectors should not be unfamiliar. We’ve all heard of military-style connectors. Do you know how the function of military connectors works? The function of connectors in production is the function of connections. But in other industries, what relevant functions will military spec electrical connectors play? Let’s take a look.

In the maintenance industry, especially in the automobile maintenance industry, the use of military-style connectors will bring us a lot of help. In the process of maintenance, after using the connector, there is no need to worry about the other operation of the machine, and no need to worry about the other parts of the car stopping because of the repair.

Another function of connectors is that when military electrical connector are used, they will have different shape design requirements. Each type of connector will have its application requirements. Of course, in actual use, we can also choose to use some connectors with shape requirements.

Military style connectors will always have different applications in different industries, but in the process of application are different, the main role of connectors in the production process is to connect different production parts. Military connectors play a simple connection role.

Sunkye is a qualified mil spec connectors manufacturer and supplier, who support custom connectors for a complete range of high-performance applications. A wide variety of military connector options are available to you, feel free to contact us.

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Sunkye’s Glass-Metal Feed-through Offers Reliability in Demanding Subsea Environments

High-pressure and high pressure feedthrough, the single- and multi-channel hpht penetrators are designed to operate reliably in the extreme environments typically found in subsea oil and gas applications.

When the subsea well gets deeper and deeper, temperature and pressure increasingly raise, it’s a huge challenge to the materials and technology of connectors. Sunkye’s glass to metal feed through seal connectors are doing well in electrical signals communication from downhole pressure and temperature sensors in subsea oil and gas environments.

Glass-to-metal seals providing the main protection and electrical isolation for the feed-through metallic contact from the external seawater environment while ensuring the highest level of reliability under long-term installation at extreme pressures and temperatures.

As one of the professional electrical d sub connector suppliers, Sunkye is uniquely qualified to deliver turnkey custom solutions for a complete range of High-Pressure, High-Temperature (HPHT) applications. Our industry-leading materials knowledge, engineering design experience, and testing capabilities are key to achieving reliable service in the most extreme HPHT environments.

Performance of Sunkye Glass to Metal Seal Military Connectors China

Sunkye Technology of glass-sintered sealing:

■ Kovar alloy glass-sintered sealing technology;

■ Temperature control technology;

■ Purification technology;

■ Selection of low-temperature glass powder;

■ Choosing and researching of outer shell and pin material;

■ Small with space-saving, lightweight

■ Hermetic connector

■ PCB mount

■ Gold plated finish

With the increasing demand for high-density connectors in the medical market, the irreversible trend of connectors in the medical field is becoming smaller, lighter and more ergonomic. This trend strongly drives demand growth.

High-density connectors are connectors with large numbers of individual contacts such as PIN pins in a relatively small connector body. There is no clear boundary between standard power connectors and high-density connectors, but the designation of high-density connectors is usually defined by having more contact points in the same shell size.

The growing demand for high-density electrical connectors is driven by many factors, especially the size, weight and function requirements. Component size and weight have long been a key factor in many military and aerospace applications. With the increasing popularity of portable and patient wearable devices, the custom medical connector is becoming more and more important in the medical market.

To meet the growing demand for the higher density connector market, many manufacturers are developing standard and ready-made high-density connectors solutions. When connectors need to meet a specific application and the output is limited, this solution is effective and feasible.

However, the development of standard high-density connector products will be targeted. Connector manufacturers must consider a variety of characteristics when developing to meet a wide range of application needs and budget constraints. Mature connector manufacturers with industry-leading ideas can successfully use this strategy, but this strategy is not universal.

High-density connectors will continue to develop, and the trend of products will be towards miniaturization, high precision and hybrid functions. With the gradual realization of these product technologies. Engineers will surely develop new connection technologies to further improve contact density, size, weight, performance and function, and to further ensure product reliability and safety. Standards and customized solutions will greatly meet the growing demand for high-density electrical connectors in the medical market.

Sunkye is one of qualified mil spec military connector manufacturers, who support custom connectors for a complete range of high-performance applications. A wide variety of military connector options are available to you, feel free to contact us.

If you want to know more information of medical connector industry, please visit our website.

The connection forms of industrial different electronic connectors can be roughly divided into four types, and more types are currently used. Here are four industrial electrical plug types:

Threaded connection

Some common types of electrical connectors are commonly used for contacts with larger dimensions and the military electrical connector that operate in high vibration environments. This type of connection can be equipped with a fuse to prevent loosening after the connection is completed. The connection is reliable, but the connection is slow.

Bayonet connection

This is a reliable and fast form of connection and disconnection. Most electrical mil connectors in the form of a card 121 connection have a visual display of proper connection and locking, and can be seen through a small hole on the side of the electrical connector’s connection nut.

In-line connector

This is a versatile form of connection. When the plug and military socket of the electrical connector are connected and disconnected, the moving direction is usually a reciprocating linear motion, without twisting and rotating, and only requires a small working space to complete the loading and unloading. Common plug-in connections come in spherical or pin configurations. Because there is no mechanical labor-saving mechanism in the connection form, once it is inserted incorrectly, the mechanical resistance increases significantly and can be found in time.

Electrical connector cabinet connection

This is an electrical connector used on some devices and requires a blind connection near the frame. It can make electrical equipment lighter, smaller, easier to maintain and more reliable.

This type of connection prevents the operator from feeling the connection. It is necessary to design an accurate positioning device to avoid forcibly connecting the wrongly inserted micro electrical connectors together, so that the wrong insertion cannot be performed. Cabinet-type electrical connectors are usually designed with floating or resilient contacts to ensure proper connection.

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Sunkye is uniquely qualified to deliver turnkey custom solutions and Mil-Spec military connectors manufacturer for a complete range of high-performance applications. Our industry-leading materials knowledge, engineering design experience, and testing capabilities are key to achieving reliable service in the most extreme environments. You’ll find a large selection of popular Mil-Spec military connectors such as MIL-DTL-83513 micro connector, MIL-DTL-38999 iii connector, MIL-DTL-32139 nano connector, MIL-DTL-26482 automotive connector, d-sub, micro-d connectors, and more, available in standard or custom configurations of mil connector.