Advertorial feature
Electrical engineering design with high density aerospace connections
H
igh speed data collection, presentation and constant processing of avionic circuitry has become one of the key elements in operating the complex infrastructure of today’s aerospace
instruments. Newer gallium arsenide, (GaAs), circuitry, as well as other high speed digital systems, have become more efficient and compact. As a result, circuit power delivery systems are smaller and wiring between electronic elements can be lightweight and fit into the higher density modules. The new circuits also operate on much lower voltages at minimal current levels that enhances higher data transmission rates than older systems. These compact designs now use miniature connectors to route data from sensors, to processing centers and onto displays and control instruments within the aerospace system. The industry can offer designers, well established avionic and aerospace qualified connectors in miniaturized sizes with high density pin-to socket systems. Standard Micro and Nano-sized connector designs are available that exceed military specifications, such as MIL-DTL- 83513 for Micro-D connectors with leads at .050”, (1.35mm), spacing or as with MIL-DTL- 32139 for Nano-D connectors with leads at .025”, (.635mm.) spacing. These connectors work well at both electrical and mechanical performance levels and have an extended history for use from rugged battlefield terrain to satellites and deep space expectations. Miniature connector pins are built with rugged BeCu, (beryllium copper) tempered to exceed the high shock and vibration needs in the aerospace industry. The contacts are plated to ASTM standards using a Nickel barrier that is over-plated with Gold for low resistance contacts and extended mating and de-mating cycles. A line of miniature connectors is designed specifically to handle high density, low-weight circuits as edge connectors for high resolution cockpit displays. Other formats fit within autonomous drones and satellites. The industry is using Nano-strip connectors ranging well beyond 50 pins per section to drive expanded cockpit displays such as those showing data from phased-array
Power-Plus Signal Miniature Connectors
radar systems. Lidar imaging systems used on drones and other multi-spectral imaging devices can require analog to high-speed digital connector methods to assist microwave transmission to control centers. Rugged, small and lightweight connectors retain signal integrity during constant vibration as well as occasional shock from landings.
As avionic constellations are evolving, connectors are being employed to assist in high density, low-profile electronic module design and layout. A combination of standard designs is directly available from connector companies and their distributors. In addition, the connector industry has become very advanced and modernized with its design and prototyping options. High density connectors can include a mix of
power, digital data and analog signal capabilities within one interconnect system. Design engineers needing customized connectors, can work directly on-line with connector developers using solid- modeling software. When the design looks good, a 3-D model can be printed over-night and sent to the designer to insure it fits both his technical and physical needs. When approved, the prototype lab can construct a first-working model using materials and processes previously proven to meet the rugged reliability needs in military and other rugged applications.
Cabling has also evolved dramatically to provide rugged density and offer higher performance interconnections. Round wire cable designs are much smaller in diameter and often use multiple strand wiring with flexible insulation to allow tight bend radius. High speed differential signal sets include two signal wires plus a captive drain wire. These sets are isolated within the cable and shielded from outside EMI and or cross- talk concerns. Within the same cable, power and other analog signals can be included as needed. Flat flexible circuits are used for connecting multiple stacks of circuit boards in designs like those in 3-D cube satellites. Mixed ridged and flexible circuits are used to connect and support higher density sensor modules. Some flexible circuits have lead sets spaced and insulated to handle today’s higher speed digital signals. Miniature connectors are selected to have pin and socket systems designed to directly match both round cable as well as perfectly align with flex circuitry. Today’s high density, interconnection technologies are well established and used extensively throughout the aerospace and avionics industry. Omnetics miniature connectors are extensively used in applications from the Mars rover program to todays advanced military aircraft and onto drones and low elevation satellites.
www.omnetics.com
Aircraft Cockpit System
EVTOL Drone Ckt. and Connectors
Omnetics Aerospace Connector Demo board
www.electronicsworld.co.uk April 2021 37
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