Reliability of Aerospace Electrical Connectors (2)

2. Use Reliability

The electrical connector will encounter electrical, thermal, mechanical and chemical stresses during use. If the correct selection and storage and use are neglected, even if the product after secondary supplementary screening is used, it will still fail.

In particular, with the continuous emergence of many new electrical connectors such as miniaturization, high density, and multi-function in recent years, many design technicians have not correctly mastered the use of these new military style electrical connectors, resulting in failure cases due to improper use. A large proportion of the failure statistics of the entire electrical connector.

(1) Selection reliability

The most appropriate electrical connector model should be selected according to the actual requirements on site, mainly considering the following factors.

① Electrical parameters: working voltage (take one-third of the withstand voltage value), rated current, contact resistance of inner and outer conductors, characteristic impedance, voltage standing wave ratio, shielding performance and anti-interference performance, etc.;
② Mechanical parameters: vibration impact, collision mechanical life, single-hole separation and total separation force, etc.;
③ Environmental parameters: temperature, humidity, vibration, impact, salt spray, dust, radiation, electromagnetic interference and sealing performance (including leakage rate, water pressure, rain), etc.;
④ Safety parameters: insulation resistance, voltage resistance, flame resistance, quality, etc. between the contacts and between the contacts and the shell;
⑤ Termination method: welding, crimping, winding, puncturing connection, screw connection, etc.;
⑥ Structural form: the detachability of the contact, the type and structure of the contact, etc.;
⑦ Connection and locking methods: bayonet type, in-line type, threaded connection type, central threaded rod type, etc.;
⑧ Installation method: panel type, cable type, nut type, through-wall type, etc.;
⑨ Operation suitability: operation space size, anti-misoperation structure, connection in-position indication, etc.;
⑩ Tail attachment form;
⑪ Overall dimensions;
⑫ The appropriate quality grade should be selected according to the role and position in the whole system;
⑬ Choice of interface profile. The Q value of the rated current of the contact should be checked according to the number of cores actually used;

The rated current of the contact is calculated by the following formula according to the current carried by the contact. The rated current of a single contact ≥ the current carried by a single contact / (1-Q), and then the mating diameter of the contact is found based on the calculated rated current of the contact.

Finally, select the desired military grade electrical connectors type spectrum. Note that the diameter of the cable core and the wiring hole of the contact should be matched to avoid damage to the terminal of the contact by an excessively thick core.
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