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Interconnection


Battlefield connector developments


Manufacturers of military electronics have many connector options available to them I


n this article, ODU evaluates some of the limiting factors in connector selection, which led to the launch of the new ODU-AMC Series T connector, and compares five popular styles of threaded and twist-locking military connectors.


Durability The more durable the product, the longer it can remain in service - think about the routine, ordinary use of the product - repeated with realistic frequency. For example, LCD-display life (or half-life), is commonly measured in hours of use, with many capable of operating continuously for ten+ years. Similarly, key pads are measured in clicks, with a capability of millions of clicks - operational for decades. So, what about the connectors used on these systems? Unfortunately, many are only capable of withstanding 500 mating cycles or less, before their performance begins to deteriorate. Although there is no 'standard- use' case, it might be reasonable to assume that any electronic equipment that’s carried by a soldier will be connected/disconnected


options appear to outshine the rest: MIL-DTL-55116 connectors and ODU-AMC Series T connectors.


For MIL-DTL-55116 connectors, this is explicitly defined by the 'water immersion' requirement.


available, an example is helpful - we used a system requiring a minimum of 20 signal lines of 0.5mm wire. Unfortunately, this requirement would exclude the MIL-DTL-55116 option, which offers only a maximum of 6 contacts, so the four remaining options would be: ■ MIL-DTL-38999 Series III with C35 insert. ■ MIL-DTL-38999 Series II with 12-35 insert. ■ Miniature 38999 with 20-contact insert. ■ ODU-AMC Size 3 with 26-contact insert. All four options would satisfy the requirement, but the space envelope is vastly different, with the smallest over 30 per cent smaller than the largest. Furthermore, it’s relevant to point out that the ODU-AMC threaded connector contains 26 contacts in the specified space, whereas the others offer only 20 or 22 contacts.


Ingress protection


A second consideration is the protection of sensitive electronics from damage. Ingress Protection ratings [IEC standard 60529] rates the degree of protection provided by electrical enclosures against intrusion by body parts, dust and water. Specifically, IP67 requires that the device under test must be capable of total immersion in water at a depth of one metre for a minimum of 30 minutes.


However, when examining the IP specifications in detail, there are particulars that are omitted. For example, IP67 specifies that “Ingress of water in quantities causing harmful effects shall not be possible...” not completely prohibiting the entry of water; just a harmful amount. Additionally, IP68


requirements are only loosely specified as “under conditions which shall be agreed between manufacturer and user but which are more severe than for numeral 7”. Further, many mil-spec connectors are not actually IP-


every day for at least half the year. It therefore follows that, depending on the choice of connector, many could be limited to less than two years of use before needing to be serviced.


If the application warrants a twist-lock or threaded mating system, two connector


28 October 2021


rated, but instead reflect specific-use test standards. Therefore, comparing these standards is highly subjective and beyond the scope of this article. Instead, we considered only whether or not the products have been tested to a standardised method for fluid ingress protection:


Components in Electronics


For MIL-DTL-38999 and Miniature 38999 connectors from the “altitude immersion” requirement. For ODU-AMC Threaded connectors, sealing properties are according to IP rating.


Size


Most connectors offered for use in military and industrial applications are based on long- established, bulky shell sizes. For many


Flexibility The new generation of battlefield equipment is not only smaller and lighter, but is more mobile and is, for example, often used both inside and outside an AFV. Several equipment OEM’s have expressed frustration at having to decide, at the design stage, the exact kind of locking mechanism to be used with each bulkhead connector. So, in response to this, ODU have launched another new addition to the Advanced Military Connector range - the ODU-AMC Series T . The ‘T’ stands for ‘Triple’ as three


locking variants of plug can fit the same receptacle:


• Push-pull – for ease of use in regular equipment hook-up • Break-away – for emergency snatch disconnection • Screw locking – for more permanent connections, with high- vibration resistance. Now OEM’s have a free choice of appropriate plug locking mechanism at each connection


applications, including soldier-wearable technology, ground robotics and in-vehicle communications, flange-size represents a critical dimension. This determines the minimum distance between connectors, or the distance to a side wall. For enclosure environmental protection, a jam nut receptacle with O-ring is preferred. To objectively compare the options


point, whilst utilising the same bulkhead receptacle fitted right across the equipment. This article quotes extracts from an ODU White Paper: https://www.odu-


usa.com/fileadmin/redaktion/downloads/dow nloadcenter/Whitepapers/ODU_Threaded- connectors_whitepaper.pdf


www.odu-uk.co.uk www.cieonline.co.uk


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