Electrical connectors are ubiquitous in military and aerospace operations, and inseparable from the ground-to-satellite communication equipment and spacecraft circuitry they support. As the interconnection of transmission signals and power, we depend on connectors for so much of our daily processes on the earth and elsewhere, in space. In order to stand up to the harsh environments they are regularly exposed to, aerospace electrical connectors must meet a strict set of requirements pertaining to their design and capabilities. In this blog, we will delve into how and why connectors are used in aerospace technology including information about their standard of quality, and the various different types of connectors available for purchase and use in aerospace operations.
In basic terms, electrical connectors are devices that connect one electrical circuit to another. Most connectors are made of two main parts: housing and terminals. The housing is the case or structure used to hold the terminals in order to stabilize the connection and protect the contacts from environmental hazards. Terminal pins are the pieces in a connector which provide the electrical conduction that makes the connection. Aerospace electrical connectors have the same basic structure but have been especially designed to meet specific requirements related to their unique environment.
These requirements include that the connector must be put through stringent testing for outgassing (the release of trapped air) and residual magnetism (which can interfere with other mechanisms) to be suitable for use in airspace and aerospace applications. Meanwhile, the connector must match for system requirements including characteristics such as anti-irradiation, high-performance vacuum outgassing, adaptability to both ultra-high and ultra-low temperatures, prevention of harmful gas intrusion, anti-condensation abilities, and be non-magnetic. To fit their unique mission, connectors must also be lightweight and compact, and must be able to withstand harsh environmental factors such as shock, extreme temperatures, and vibration. Space grade connectors have standards of MIL-C-5015, MIL-C-26482, MIL-DTL-38999, MIL-DTL-55302, MIL-DTL-83513, and MIL-DTL-32139.
Aerospace connectors can be categorized based on their connection modes, shape, and working frequency. According to the connection modes, there are threaded connection, bayonet (quick) connection, bayonet lock connection, push-pull connection, and direct plug connection type connectors. Connectors can also either be circular or rectangular and may operate at either high or low frequency. Besides these characteristics, aerospace connectors can be classified by their electrical performance (rated voltage, rated current, contact resistance, etc.) , mechanical properties (number of contact pairs and pinholes, shell material, contact type, etc.), and environmental technical performance (working temperature, working height, vibration, moisture resistance, etc.).
Three major categories of connectors are used in space flight applications: D-subminiature, micro-miniature, and circular. When an engineer is selecting a connector for use in space, they must consider the type of application and size requirements as well as factors in its environment. D-subminiature and Micro-D connectors are widely used on PCB, panel mount, and basic cable systems, while circular connectors are used for heavy-duty cable and panel mount operations.
In conclusion, aerospace electrical connectors are valuable junctions for transmission signals and power used aboard spacecraft and satellite systems. These devices are subjected to stringent testing to be rated safe and effective for extraterrestrial use. Among all the aerospace connector distributors, Alpha Industrial Parts rises above and beyond industry standards to provide our customers with the smoothest procurement process on the market. We make sure our easy-to-navigate online inventory of aerospace and aviation components is available to our customers with competitive pricing as well as quick and convenient shipping. To begin the purchasing process, simply send us a completed RFQ form, and expect to receive a custom quote for your comparisons in just 15 minutes or less!
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