CUSTOM MICRO-D SOLUTIONS

Transcription

1 CUSTOM MICRO-D SOLUTIONS CUSTOM DESIGN CONNECTORS Custom design connectors Materials & finishes and 74 way Micro-D connectors Surface mount connectors Custom designed shells and hardware EMI & panel mount connectors Filtered Micro-D connectors Termination with flex circuits Waterproof & hermetic connectors High-density connectors Non magnetic Micro-D interconnect FROM CUSTOM DESIGN ASSEMBLIES TO MINI-SYSTEMS From assemblies to mini systems Our harnessing capabilities Technical for assemblies Overmoulding expertise SILFORM cables & assemblies Mini-systems : complete w ww.microd-connectors.com 2002, AXON CABLE SAS - AXON D-LINE - RELEASED JUNE PARTIE 1 CUSTOM.indd /12/14 16:13

2 Custom designed CUSTOM DESIGN CONNECTORS In addition to the standard range of Micro-D connectors and assemblies, AXON can develop custom designed, all based on Micro-D twist-pin contact technology. AXON is the sole manufacturer in Europe to have fully integrated in-house the design and the manufacture of the Micro-D system, including : - Twist pins, shells, inserts and interfacial seals. - Custom designed conductors, wires and cables. - Complex assembly processes including optimised EMC shielding, branch braiding and overmoulding. This high level of vertical integration enables AXON to offer complete which meet the demanding requirements of the aeronautics, space, military, industrial and off-shore markets. Common applications MIL-AERO - Missiles and counter measures. - Electro-optics. - Navigation systems. - Avionics equipment. - Radar systems. - Twist capsules. - Shoulder launched weapon systems. - Advanced soldier technology systems. - Military GPS systems. NON MILITARY - Down-hole drilling tools. - Automotive test equipment. - Medical devices. - Ruggedised computers. - Research centres. SPACE - Satellite electronics. - Space station and planetary explorer applications , AXON CABLE SAS - AXON D-LINE - RELEASED JUNE PARTIE 1 CUSTOM.indd /12/14 16:13

3 Custom designed MATERIALS & FINISHES AXON can offer micro-d with standard and special shell materials and finishes. The table below illustrates some of the more common options, however other materials and finishes may be possible on request : SALT SPRAY TEST EQUIPMENT MATERIAL IN ACCORDANCE WITH DENSITY (g/cm3) FINISH SALT SPRAY RESISTANCE (IN ACCORDANCE WITH EIA ) TEMPERATURE RANGE MISCELLANEOUS ALUMINIUM 6061 SAE AMS-QQ-A-250/ STANDARD MIL-DTL FINISHES - CADMIUM WITH YELLOW CHROMATE OVER ELECTROLESS NICKEL 96 HOURS 150 C MILITARY APPLICATIONS - ELECTROLESS NICKEL SPECIAL FINISHES 48 HOURS 200 C MOST COMMON PLATING - CADMIUM WITH YELLOW CHROMATE OVER ELECTROLESS NICKEL 500 HOURS 150 C MILITARY APPLICATIONS - HEAVY ELECTROLESS NICKEL 500 HOURS 200 C MILITARY & SPACE APPLICATIONS - BLACK ANODISATION (IN ACCORDANCE WITH MIL-A-8625 TYPE II CLASS 2) 48 HOURS 150 C NON-REFLECTIVE / POOR CONDUCTIVITY - CHEMICAL FILM IN ACCORDANCE WITH MIL-C-5541 CLASS 3 48 HOURS 150 C NON MAGNETIC APPLICATIONS - GOLD PLATING IN ACCORDANCE WITH ASTM-B-488 OVER ELECTROLESS NICKEL 48 HOURS 150 C SPACE GRADE APPLICATIONS STAINLESS STEEL SERIES PASSIVATION IN ACCORDANCE WITH SAE AMS HOURS 200 C EXCELLENT CORROSION RESISTANCE TITANIUM NONE 500 HOURS 200 C KOVAR (Fe/Ni/Co ALLOY) ELECTROLYTIC NICKEL ALL ROUND PERFORMANCE WEIGHT, CORROSION, EMC 48 HOURS 200 C HERMETIC APPLICATIONS , AXON CABLE SAS - AXON D-LINE - RELEASED JUNE PARTIE 1 CUSTOM.indd /12/14 16:13

4 Custom designed 69 AND 74 WAY MICRO-D CONNECTORS AXON offers specific contact arrangements for custom applications. Specific designs are not covered by the MIL-DTL specification but AXON s connectors remain fully compatible with the MIL-DTL standard as far as performance and construction are concerned. Contact arrangements MATING FACE OF 69 WAY MALE CONNECTOR MATING FACE OF 69 WAY FEMALE CONNECTOR MATING FACE OF 74 WAY MALE CONNECTOR MATING FACE OF 74 WAY FEMALE CONNECTOR 1.27 mm (.050 ) contact spacing mm (.043 ) spacing between rows. Electrical & mechanical characteristics As per MIL-DTL SEE PAGE 15 FOR MORE INFORMATION Materials As per MIL-DTL SEE PAGE 15 FOR MORE INFORMATION , AXON CABLE SAS - AXON D-LINE - RELEASED JUNE PARTIE 1 CUSTOM.indd /12/14 16:13

5 Dimensions Dimensions are in millimetres (inches). A ± 0.25 (±.010) B max C D E F max -0.46/+0.25 ± 0.13 ± 0.25 Male female (-.018/+.010) (±.005) (±.010) Male female G max 69P/69S P/74S Available versions metal shell only - Male pigtail - Female pigtail - Saver - PCB connectors (available on request) 69 WAY MICRO-D PIGTAIL CONNECTORS 74 WAY MICRO-D PIGTAIL CONNECTORS , AXON CABLE SAS - AXON D-LINE - RELEASED JUNE PARTIE 1 CUSTOM.indd /12/14 16:13

6 Custom designed SURFACE MOUNT CONNECTORS Surface mount connectors are becoming a new industry standard for saving space between electronic Printed Circuit Boards. In comparison with a classic right angled PCB connector (BR), a surface mount connector mounted on the edge of a PCB can greatly reduce the overall space envelope required, both in surface area and in height. Thus, electronic cards can be higher in component density, and stacked more closely than before. Surface mount connectors are available in 3 versions : SMV (Surface Mount Vertical), SMT (Surface Mount Transversal - on the edge of the card) and SMH (Surface Mount Horizontal). All three styles usually have gold plated tails with a spacing of mm (.025 ). AXON offers various hardware options, either the classic jackposts and jackscrews, or more specialised options such as keying hardware. AXON Surface Mount Connectors are typically compatible with PCB s having a thickness of between 1.6 and 3.2 mm (.063 to.126 ). However, AXON can study custom surface mount connectors to meet your specific application and space requirements. SPECIAL 31 WAY SMH CONNECTOR s 51 WAY SMT CONNECTOR 51 WAY SMT CONNECTOR PCB MOUNT 37 WAY SMH CONNECTOR , AXON CABLE SAS - AXON D-LINE - RELEASED JUNE PARTIE 1 CUSTOM.indd WAY SMH CONNECTOR /12/14 16:13

7 Custom designed CUSTOM DESIGNED SHELLS & HARDWARE Your system or application may be highly specialised in size, shape, performance or construction, and for this reason the standard Micro-D shell sizes may not be suitable. Meeting the challenge, AXON can adapt existing shells or produce custom design Micro-D shells to meet your specific mechanical and environmental requirements. Design and manufacturing expertise on the same site makes it possible for AXON to offer you a quick turnaround. As we design and manufacture all the different component parts in-house, we can offer quick design for small series and large volumes. AXON is also able to develop and manufacture special hardware, such as retractable or captive screws, threaded inserts, and other configurations as required. EXAMPLES OF MICRO D SHAPE FULLY INTEGRATED INTO AN ELECTRONIC BOX COVER TO ELIMINATE RF/EMI LEAKAGE IN COMPARISON TO A CLASSIC PANEL MOUNT CONNECTOR 1 2 MICRO-D WITH SPECIAL INTEGRATED BACKSHELL FOR FLAT CABLE 1 - High position to facilitate the mating 2 - Low position to lock the connector CUSTOM MICRO-D DESIGN 51 WAY SAVER WITH CUSTOM RETRACTABLE SCREWS , AXON CABLE SAS - AXON D-LINE - RELEASED JUNE PARTIE 1 CUSTOM.indd /12/14 16:13

8 Custom designed EMI & PANEL MOUNT CONNECTORS EMI protection is a key issue for all electronics devices. Since the mid eighties AXON has had a dedicated team of engineers who specialise in this field. The AXON EMI Team has developed simulation software to predict the transfer impedance (or shield efficiency) of a connector, a cable or a complete cable assembly during the design phase before any manufacturing commences. Product tests in AXON s stirred mode chamber and transfer impedance test bench validate the simulated results. Simulation is an excellent tool to optimise a design in order to provide the best compromise between performance, weight and cost. Such simulation has proven over the years that a good component is not enough to ensure good EMI performance. In addition, it is essential to ensure the right combination and compatibility between connector, cable and the shield termination to the backshell. The AXON Micro-D backshells are specifically designed to perfectly fit the connector and prevent EMI leakage. Many other micro-d backshells are simply maintained against the connector by the hardware, but these do not offer optimised EMI performance. On request, the flange of a panel mount connector can incorporate a groove which enables an EMI o-ring or gasket to be fitted. In this case the flanges are wider than for normal connectors. SILVER PLATED FLANGE MICRO-D WITH EMI 0-RING AND 360 SCREEN TERMINATION TO EMI BACKSHELL CUSTOM ANGLED EMI BACKSHELL LARGE FLANGE MICRO-D PIGTAILS WITH EMI GASKET GROOVES (51 WAY ON THE LEFT HAND SIDE, 25 WAY ON THE RIGHT HAND SIDE) , AXON CABLE SAS - AXON D-LINE - RELEASED JUNE PARTIE 1 CUSTOM.indd /12/14 16:13

9 EMI SOLUTIONS AXON has drawn on long experience in the fields of RF and EMI protection to design and adapt the Micro-D connector to meet the most challenging of EMI environments. EMI customisation of the standard micro system can include : - EMI gaskets or o-rings - Special backshells - Special connector shell designs - Special finishes - Optimised shield termination to the backshell. 2 PART SELF-LOCKING 45 EMI BACKSHELL WITH LARGE FLANGE MICRO-D CONNECTOR HIGH PERFORMANCE EMI HARNESS - 2 part self locking EMI backshell - optimised shielding screen termination - EMI gasket - special technical for better EMI protection STIRRED MODE CHAMBER EMI BACKSHELL ON ITS OWN, AND FITTED TO A MICRO-D WITH SHIELD TERMINATION TO CABLE AND OVERALL PROTECTION MEASUREMENT OF TRANSFER IMPEDANCE , AXON CABLE SAS - AXON D-LINE - RELEASED JUNE PARTIE 1 CUSTOM.indd /12/14 16:13

10 Custom designed FILTERED MICRO-D CONNECTORS Integrated systems require more power with major current fluctuations, creating a noisy electromagnetic field. Filtered Micro-D connectors are designed to protect your equipment from this electromagnetic interference. General configuration Axon filtered Micro-D connectors are available with two different types of filters: C filter and PI filter, both low-pass. High frequency signals are attenuated, whilst low frequency and DC signals pass through. C FILTER - One capacitor per filtered pin. - Best suited for high input and output impedance and when a fast attenuation is not necessary. - When small size is needed. PI FILTER - Two capacitors on either side of an inductor per filtered pin. - Used for high impedance and a sharp attenuation. - Performances at high frequency are excellent. 9 WAY PI FILTERED BS FEMALE CONNECTOR 15 WAY PI FILTERED FEMALE PIGTAIL 37 WAY C FILTERED CBR FEMALE CONNECTOR , AXON CABLE SAS - AXON D-LINE - RELEASED JUNE PARTIE 1 CUSTOM.indd /12/14 16:13

11 Electrical & mechanical characteristics CHARACTERISTIC SPECIFICATION TEST METHOD CURRENT RATING 3 A max. EIA SIGNAL CONTACT RESISTANCE 8 mω max. EIA INSULATION RESISTANCE 5000 MΩ 500 V DC EIA DIELECTRIC WITHSTANDING VOLTAGE - SEA LEVEL 0 m 125V DC EIA CONTACT ENGAGING AND SEPARATION FORCE 170 g max. (6 oz) 14 g min. (0.5 oz) EIA CONNECTOR MATING AND DE-MATING FORCE 283 g (10 oz) x number of contacts max. EIA CONTACT RETENTION 2.26 kg (5 lbs) for 5 seconds min. EIA DURABILITY 500 mating cycles min. EIA TEMPERATURE RANGES - STANDARD -55 C / +125 C VIBRATION 20 g s -No discontinuity >1µs EIA TEST CONDITION IV SHOCK 50 g s -No discontinuity >1µs EIA TEST CONDITION E SALT SPRAY 48 hours EIA TEST CONDITION B HUMIDITY Insulation resistance > 1MΩ EIA METHOD IV Material & Finish COMPONENT MATERIAL FINISH MALE CONTACT (TWIST PIN) COPPER AND BERYLLIUM COPPER. GOLD PLATING IN ACCORDANCE WITH ASTM-B488, TYPE II, CLASS 1 (1.27µm (0.050 ) MIN.), CODE C FEMALE CONTACT CAPACITORS INDUCTORS COPPER ALLOY PLANAR CERAMIC ARRAY FERRITE OVER NICKEL UNDERPLATE IN ACCORDANCE WITH SAE-AMS-QQ-N-290 CLASS 2 (1.27µm (0.050 ) TO 3.81µm (0.150 ) ) METAL SHELL PLASTIC SHELL/ INSERT / PCB TRAY ALUMINIUM ALLOY, TYPE 6061 IN ACCORDANCE WITH SAE-AMS-QQ-A-250/11 STAINLESS STEEL, 300 SERIES LIQUID CRYSTAL POLYMER, 30% LOADED GLASS FIBRE POLYESTER, 94VO, IN ACCORDANCE WITH MIL-M (200 C) YELLOW CHROMATE OVER CADMIUM : IN ACCORDANCE WITH SAE-AMS-QQ-P-416, TYPE II, CLASS 3 ELECTROLESS NICKEL PLATING IN ACCORDANCE WITH SAE-AMS2404, CLASS 3 OR 4,.0005 INCH MIN. PASSIVATION IN ACCORDANCE WITH SAE-AMS2700 INTERFACIAL SEAL FLUOROSILICONE RUBBER IN ACCORDANCE WITH A-A HARDWARE STAINLESS STEEL, 300 SERIES PASSIVATION IN ACCORDANCE WITH SAE-AMS2700 ENCAPSULANT EPOXY RESIN PTFE INSULATED SILVER PLATED COPPER IN ACCORDANCE WITH NEMA-HP3 INSULATED WIRE PTFE INSULATED SILVER PLATED COPPER IN ACCORDANCE WITH SAE-AS22759/11 ETFE INSULATED SILVER PLATED COPPER IN ACCORDANCE WITH SAE-AS22759/33 UNINSULATED WIRE GOLD PLATED SOLID COPPER WIRE IN ACCORDANCE WITH A-A TIN PLATED SOLID COPPER WIRE IN ACCORDANCE WITH A-A , AXON CABLE SAS - AXON D-LINE - RELEASED JUNE PARTIE 1 CUSTOM.indd /12/14 16:13

12 Electrical characteristics of the filters Frequency khz 1 MHz 10 MHz 100 MHz 1 GHz Attenuation (db) WAY PI FILTERED BS FEMALE CONNECTOR ATTENUATION OF THE AXON 9 WAY PI FILTER WITH A CAPACITANCE OF PF Contact arrangements Axon filtered Micro-D connectors are available in 7 sizes, from 9 to 51 contacts on 2 rows. They are fully intermateable with standard Micro-D connectors. MATING FACE OF MALE RECTANGULAR CONNECTOR mm (.050 ) contact spacing mm (.043 ) spacing between rows. 9 CONTACTS 15 CONTACTS 21 CONTACTS 25 CONTACTS 31 CONTACTS 37 CONTACTS 51 CONTACTS DUAL ROW , AXON CABLE SAS - AXON D-LINE - RELEASED JUNE PARTIE 1 CUSTOM.indd /12/14 16:13

13 MATING FACE OF FEMALE RECTANGULAR CONNECTOR mm (.050 ) contact spacing mm (.043 ) spacing between rows. 9 CONTACTS 15 CONTACTS 21 CONTACTS 25 CONTACTS 31 CONTACTS 37 CONTACTS 51 CONTACTS DUAL ROW Axon standard range of filtered Micro-D CBR CONDENSED RIGHT ANGLE MOUNT CONNECTORS BS VERTICAL MOUNT CONNECTORS PIGTAIL CONNECTORS , AXON CABLE SAS - AXON D-LINE - RELEASED JUNE PARTIE 1 CUSTOM.indd /12/14 16:13

14 PCB filtered connectors BS CONNECTORS TYPE PITCH METAL SHELL DIMENSIONS Dimensions are in millimetres (inches). A ± 0.25 (±.010) B ± 0.13 (±.005) C max D max F max E max Male Female Male Female C filter PI filter 9P / 9S P / 15S P / 21S P / 25S 31P / 31S 37P / 37S , AXON CABLE SAS - AXON D-LINE - RELEASED JUNE PARTIE 1 CUSTOM.indd /12/14 16:13

15 PCB LAYOUT FOR FILTERED BS TYPE PITCH MALE CONNECTORS 9 CONTACTS - view A 15 CONTACTS - view A 21 CONTACTS - view A 25 CONTACTS - view A 31 CONTACTS - view A 37 CONTACTS - view A , AXON CABLE SAS - AXON D-LINE - RELEASED JUNE PARTIE 1 CUSTOM.indd /12/14 16:13

16 PCB LAYOUT FOR FILTERED BS TYPE PITCH FEMALE CONNECTORS 9 CONTACTS - VIEW A 15 CONTACTS - VIEW A 21 CONTACTS - VIEW A 25 CONTACTS - VIEW A 31 CONTACTS - VIEW A 37 CONTACTS - VIEW A , AXON CABLE SAS - AXON D-LINE - RELEASED JUNE PARTIE 1 CUSTOM.indd /12/14 16:13

17 CBR CONNECTORS METAL SHELL DIMENSIONS Dimensions are in millimetres (inches). A ± 0.25 (±.010) B ± 0.13 (±.005) C max D max F max G max H max E max Male Female Male Female C filter PI filter C filter PI filter C filter PI filter 9P / 9S P / 15S P / 21S P / 25S 31P / 31S 37P / 37S , AXON CABLE SAS - AXON D-LINE - RELEASED JUNE PARTIE 1 CUSTOM.indd /12/14 16:13

18 PCB LAYOUT FOR FILTERED CBR TYPE PITCH - MALE CONNECTORS VIEW A 9 CONTACTS - VIEW B 15 CONTACTS - VIEW B 21 CONTACTS - VIEW B 25 CONTACTS - VIEW B 31 CONTACTS - VIEW B 37 CONTACTS - VIEW B , AXON CABLE SAS - AXON D-LINE - RELEASED JUNE PARTIE 1 CUSTOM.indd /12/14 16:13

19 PCB LAYOUT FOR FILTERED CBR TYPE PITCH - FEMALE CONNECTORS VIEW A 9 CONTACTS - VIEW B 15 CONTACTS - VIEW B 21 CONTACTS - VIEW B 25 CONTACTS - VIEW B 31 CONTACTS - VIEW B 37 CONTACTS - VIEW B , AXON CABLE SAS - AXON D-LINE - RELEASED JUNE PARTIE 1 CUSTOM.indd /12/14 16:13

20 Pigtail connectors DIMENSIONS Dimensions are in millimetres (inches). 9P / 9S 15P / 15S 21P / 21S 25P / 25S 31P / 31S 37P / 37S 51DR P / 51DR S A ± 0.25 (±.010) B max C D E F max H max -0.46/+0.25 ± 0.13 ± 0.25 G max PI Male female (-.018/+.010) (±.005) (±.010) Male female C filter filter , AXON CABLE SAS - AXON D-LINE - RELEASED JUNE PARTIE 1 CUSTOM.indd /12/14 16:13

21 Custom designs Please contact Axon to request special designs of filtered Micro-D connectors. A few examples of custom-made connectors are illustrated below. 37 WAY PARTIALLY C-FILTERED CONNECTOR FILTERED CONNECTOR 37 WAY FILTERED CONNECTOR PLANAR FILTER WITH SELECTIVE FILTERING 37 WAY C-FILTERED PANEL MOUNT CONNECTOR WITH EMI PROTECTION CUSTOM FILTERED BS CONNECTORS , AXON CABLE SAS - AXON D-LINE - RELEASED JUNE PARTIE 1 CUSTOM.indd /12/14 16:13

22 Custom designed TERMINATION WITH FLEX CIRCUITS AXON offers Micro-D connectors with flexible printed circuit (FPC) termination as an alternative to standard wire pigtails. Likewise, AXON can design and produce complex, multi-branched harnesses with flex circuits for applications where wire or cable are not suitable in terms of space envelope, process or application usage. Flex (or flexi-rigid) circuits are custom designed to meet the customer s specific requirements, and can be tailor made to a multitude of shapes and constructions. Please contact us for all your specific flex circuit assembly requirements. MULTIBRANCHED FLEXIBLE PRINTED CIRCUIT WITH MICRO-D TERMINATION ASSEMBLY WITH FLEXIBLE PRINTED CIRCUIT CONNECTOR TERMINATION WITH FLEXIBLE PRINTED CIRCUIT , AXON CABLE SAS - AXON D-LINE - RELEASED JUNE PARTIE 1 CUSTOM.indd /12/14 16:13