INTERCONNECTION FEATURE THE DRIVING DEMANDS OF MOTORSPORT
High performance connectors are put to the test in the harsh conditions of motor sport racing. Peter Costin at Lane Motorsport investigates the latest design capabilites in response
N
o other environment will test the reliability and integrity of electronic
components like motorsport. Extremes of temperature, vibration, water, oil and sometimes violent impacts can all combine to provide a severe test for all types of components - particularly electronic connector systems. So demanding are the environmental
conditions that purpose designed electronic connectors have been developed to meet the specific needs of the motorsport industry. These are lightweight, ultra-small circular connector systems that maintain total contact integrity whatever the extremes of temperature and vibration while also resisting the ingress of water, oil and other liquids and gases. Because of the nature of motorsport, in all its forms, connector systems must be designed to make installation and replacement a simple, quick and completely reliable operation. Designed in line with recognised military and aerospace standards, these high performance connectors are used in many areas including batteries, starters and alternators, fuel pumps, fuel tanks, engine control units, communications equipment, data acquisition systems and harnesses. Their design and construction enables them to overcome the environmental demands while meeting the performance, size and weight constraints specified by designers of the latest motorsport systems. As well as meeting the exacting performance levels, the connectors also need to be available on demand and in any quantity. Only a handful of manufacturers and
suppliers can meet the level of performance demanded by the motorsport sector and fewer still are set-up to respond in just 24 hours to requests for such specialist connectors. As an “Assembling Distributor” for Souriau, FC Lane’s Motorsport Division was established to do just that. The company holds a significant inventory of standard circular connectors and an even larger stock of connector piece parts ready to be assembled, tested and despatched. These can be specified and ordered from Lane Motrosport’s online click to connect store.
8STA – THE STANDARD FOR MOTORSPORT The Souriau 8STA Series of circular connectors consists of several connector types, each designed to meet specific motorsport applications. These connectors
/ ELECTRONICS
of 500 mating cycles. Like all 8STA connectors, the operating temperature is – 55ºC to 175ºC and, when mated, the connector meets the requirements of IP67 which means it can withstand salt spray and other motorsport fluids. The 8STA Power connector will accept a
wide range of wire sizes and is ideal for high power applications up to 200A continuous. Ideal for batteries, starter motors and alternators for example, a key advantage of this connector is its ability to incorporate mixed contact types which allows a single connector to transmit both signal and power. The 8STA High Density connector series
is among the smallest and lightest circular connector of its type currently available and its high density capability provides up to 68 size 26 contacts using 24 to 30 AWG wire. This allows a smaller shell size to be used for the same application. Seven shell sizes in seven layouts are available from size 02 to 14. Contacts are gold plated copper alloy with liquid silicone rubber insulator and seal. The size 26 contacts are rated at 3A. They can handle 500 mating cycles, 300g shock for 3ms and vibration levels to 147m/s2, 10 to 2000Hz.
Figure 1 & 2:
Miniature connectors for the harsh demands of motorsport from Lane Motorsport
are available in a wide variety of shell sizes and all feature quick bayonet locking with visual indication when mated. These connectors are available in a variety of receptacle styles including Jam Nut, Oval Flange, In-Line and Through Bulkhead. Souriau 8STA connectors can be found in Formula 1, Indy cars, GP2, World rally cars, endurance racing including Le Mans 24 hours as well as World Superbikes and Moto GP.
MINIATURE CIRCULAR CONNECTORS The series also includes one of the industry’s smallest circular connectors, the Size 02. This is derived from established military specifications MIL-DTL-38999 and JN1003 and its ultra-compact design and lightweight construction make it ideal for connecting sensors and other complex electronic systems. Featuring a rugged aluminium body,
plated with conductive black Zinc or Nickel as standard, the connector incorporates a positive locking mechanism with locked colour indicators. Designed to be scoop proof, this Size 02 connector is fitted with removable gold-plated copper alloy contacts and features an endurance level
MOTORSPORT ACCESSORIES As well as the circular connectors themselves, Lane’s Motorsport Division supports the 8STA portfolio with a variety of accessories designed to suit motorsport applications. Produced by Weald Electronics and HellermannTyton, these include nut plates and gaskets for all 8STA shell sizes from 02 to 24 as well as heat- shrinkable protective boots specially formulated to combine high electric strength, mechanical toughness and superior chemical and environmental resistance. Lane also recently announced a series of lightweight protective caps designed specifically for motorsport applications. Machined from solid aluminium, they provide a corrosion resistant cap for AS/8STA connector plugs and receptacles.
According to the company, the caps are up to 35% lighter than current models, feature an anti-vibration locking design and can be supplied with or without a flexible, stainless steel micro wire rope lanyard.
Lane Motorsport
www.lanemotorsport.com T: 01403 790 661
ELECTRONICS | MAY 2016 15
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