high-voltage connectors Archives - Connectronics Corp.

Posted by Rylee Fryer on November 16, 2024 7:15 am | Leave a Comment

Aerospace connectors, also known as avionics connectors, are specialized components utilized to connect electrical systems in aircraft. They are designed to withstand extreme environmental conditions, including high altitudes, temperature variations, and vibration. These connectors ensure reliable communication and power transmission between different onboard systems, such as navigation and control systems.

In this article, we will look at the types of avionics connectors, their applications, and their role in the demanding aerospace environment.

Roles of Connectors in the Aerospace Sector

Below are the different roles of connectors, each playing a vital part in ensuring the reliability and safety of aircraft systems:

Power Distribution

Connectors are crucial in power distribution within aircraft by ensuring that electrical power is delivered reliably to several systems. They connect power sources — such as generators or batteries — to critical systems, including avionics, lighting, and propulsion.

Data Transmission

High-speed and reliable data connectors are vital for maintaining the integrity and performance of aerospace systems. They ensure that data is transmitted with minimal loss and interference, essential for accurate navigation and effective aircraft control.

Signal Routing

Aerospace connectors route different signals, including control signals, sensor inputs, and feedback. They are vital for connecting sensors to data acquisition systems and control units, enabling the aircraft to respond accurately to operational commands.

Communication Systems

Robust connectors are essential for maintaining effective communication channels and ensuring safety and coordination. These components guarantee reliable and clear communication between the aircraft, ground control, and crew members.

Avionics Integration

Connectors support the integration of several avionics systems, enabling different components to work together. They also connect flight management systems, autopilots, and display panels, which allow for integrated operation and management of the aircraft’s avionics suite.

Maintenance and Upgrades

Different aerospace connectors facilitate the maintenance and upgrading of aerospace systems by enabling modular and easily replaceable connections. This modularity allows for quick repairs and replacements, minimizing downtime and maintaining the aircraft’s operational readiness.

Types of Aerospace Connectors and Their Applications

The following types of connectors contribute to the reliability and functionality of aerospace systems:

Circular Connectors

Circular connectors are widely used in aerospace applications due to their robust design and ease of use. They are cylindrical and can have multiple pins for connecting different electrical signals. These components are commonly used in avionics, control systems, and power distribution because they provide secure connections in harsh environments.

Rectangular Connectors

Rectangular connectors are designed to accommodate a high density of contacts in a compact space. They are mostly used in applications where space is limited and many connections are required. They are commonly found in cockpit displays, communication systems, and flight control units due to their reliability and space efficiency.

Radio Frequency (RF) Connectors

RF connectors are essential in aerospace applications for communication systems, radar, and navigation equipment. They are engineered to minimize signal loss and interference, ensuring clear and dependable communication. They come in several types — such as SMA, BNC, and TNC — each suitable for different frequency ranges and applications.

Fiber Optic Connectors

Fiber optic connectors are used in aerospace applications due to their ability to handle large amounts of data and their resistance to electromagnetic interference. They are commonly employed in data networks, in-flight entertainment, and advanced communication systems. These components also provide high bandwidth and are ideal for long-distance signal transmission in aircraft.

D-Sub Connectors

D-Sub connectors are known for their unique D-shaped metal shield, which provides mechanical stability and reduces electromagnetic interference. These components are utilized in avionics and other systems for data transmission and control signals. They also come in different sizes and pin configurations, making them versatile for aerospace applications.

Discover Reliable Solutions With Connectronics Today!

Connectronics stands at the forefront of aerospace connectivity, offering innovative solutions that ensure reliability, performance, and safety for your critical systems. Our connectors are engineered to meet the highest standards, which provide you with the peace of mind needed for seamless operations.

Contact us to learn how our cutting-edge technology can elevate your aerospace systems and drive your success! You can also request a quote to get started.

Posted by MJAnderson on August 14, 2024 5:45 am | Leave a Comment

High-voltage electrical connectors are essential for circuits operating above 60V and critical components in automotive and industrial applications. They facilitate the transmission of high currents — particularly in electric vehicles — linking vital elements such as battery packs, motor controllers, and chargers.

This article explores the crucial role of high-voltage electrical connectors in diverse industries. We will delve into their applications, materials, and safety considerations, particularly in high-power environments.

Materials Used in High-Voltage Electrical Connectors

The following are the key materials utilized in the development and use of high-voltage connectors:

Conductive Materials

High-voltage connectors rely on conductive materials engineered for efficient transmission of heavy currents. Commonly used materials include:

Copper: This is known for its excellent conductivity and mechanical properties, carrying heavy currents effectively.
Copper alloys: Various copper alloys, such as brass and bronze, are utilized in high-voltage electrical connectors to enhance specific properties such as strength, corrosion resistance, and conductivity.
Silver: This boasts superior conductivity compared to copper and is sometimes used in specialized high-performance connectors where maximum conductivity is required.

Insulating Materials

Insulating materials prevent electrical leakage and ensure the safety and reliability of the system. Commonly used materials in high-voltage connectors include:

Polyethylene: This is known for its excellent dielectric properties and mechanical resilience.
Polypropylene: Similar to polyethylene, polypropylene offers good dielectric properties and mechanical strength.
Silicone rubber: This is highly valued for its flexibility, thermal stability, and resistance to environmental factors.

Factors Influencing Connector Design

Listed below are the factors influencing design decisions and safety considerations in high-voltage electrical connectors:

High Voltage and Current Performance

High-voltage connectors must be designed to handle the elevated voltage and current levels present in high-power environments. This involves selecting materials and configurations that efficiently conduct electricity while minimizing resistance and heat generation. Connectors must also maintain stable electrical properties at high voltages and currents to ensure reliable performance and safety.

Environmental Protection

Electrical connectors often face harsh environmental conditions, including high temperatures, vibrations, impacts, dust, and water exposure. Design decisions must prioritize integrating protective measures to ensure the connectors withstand such conditions without degradation. Environmental protection guarantees connectors remain undamaged and reliable in tough situations.

Ease of Installation

High-voltage connectors should be designed for easy installation to minimize downtime and ensure efficient system integration. This involves connector form factor, mounting options, and connector interface compatibility. Connectors should feature intuitive designs and standardized connection methods to simplify installation and minimize installation errors.

Electromagnetic Shielding

These connectors should possess effective shielding capabilities to prevent electromagnetic interference (EMI) and ensure signal integrity in sensitive electronic environments. This includes using shielding materials and designs to reduce electromagnetic emissions and prevent external interference. Effective electromagnetic shielding maintains signal quality in noisy environments.

Applications of High-Voltage Electrical Connectors

Here are the diverse applications of high-voltage connectors and their significance in each domain:

Power Generation and Distribution

High-voltage connectors are instrumental in power generation and distribution, ensuring reliable long-distance electricity transmission. They interconnect high-voltage cables, transformers, and other electrical components in power plants and substations. These connections maintain the efficiency of the electrical network from power stations to end-users.

Industrial Machinery and Equipment

In industrial settings, high-voltage connectors are vital for powering heavy machinery and equipment. They facilitate the safe transmission of electricity to motors, actuators, and control systems. Manufacturing, mining, and transportation industries rely on these connectors to uphold productivity and improve tasks such as powering conveyor belts and operating cranes.

Renewable Energy Systems

These connectors facilitate renewable energy transmission to the grid by interconnecting solar panels, wind turbines, and other components that ensure efficient energy conversion and distribution. As the demand for clean energy increases, high-voltage connectors will continue to support the transition to renewable sources.

Choose Connectronics for Reliable High-Voltage Connectors

At Connectronics Corp., we understand the vital role of high-voltage electrical connectors in different industries. With over 300 years of combined experience in connector technology, we deliver top-notch solutions that exceed industry standards. Our solutions ensure safe electrical transmission even in the most challenging environments.

Posted by MJAnderson on 5:40 am | Leave a Comment

A high-voltage connector is designed to safely and reliably transmit electricity in settings with voltages above standard levels. It is engineered to withstand high levels of electrical stress and prevent arcing or insulation breakdown. This makes it suitable for various applications, such as power generation, distribution, transmission, electric vehicle (EV) manufacturing, and industrial machinery.

Over the years, high-voltage connector technology has evolved to meet the increasing demands for safety, efficiency, and reliability in electrical systems. Here are some of the most notable innovations:

1. Compactness and Miniaturization

Engineers strive to reduce the size and weight of a high-voltage connector while maintaining or even improving its performance characteristics. This innovation is particularly crucial in applications where space is limited, such as in EVs and portable electronic devices. A compact connector can also improve system efficiency by minimizing energy losses and optimizing space utilization.

2. Cybersecurity Features

With the rising digitalization of power systems and the advent of smart grid technologies, cybersecurity features are becoming more crucial in high-voltage connections. Connector design innovations include built-in security mechanisms like encryption, authentication, and intrusion detection. They guard against cyber attacks and ensure data integrity in digitalized power networks.

3. Environmental Sustainability

In response to increasing environmental concerns, there is a growing emphasis on developing more environmentally friendly high-voltage connectors. This includes using recyclable materials in the manufacturing process. Manufacturers are also exploring ways to minimize energy consumption during production by implementing energy-efficient methods.

4. High-Frequency Capabilities

With the increasing popularity of high-frequency power transmission systems, there has been a focus on developing high-voltage connectors that can handle such signals. These connectors are engineered to minimize signal losses and electromagnetic interference, ensuring efficient power transfer in applications like renewable energy systems. They are also suitable for telecommunications infrastructure, radar systems, medical equipment, and high-speed data transmission networks.

5. Integration of Smart Features

Modern high-voltage connectors incorporate features that enable real-time monitoring of connector health, temperature, and performance parameters. These allow for predictive maintenance and enhanced reliability. Examples of smart features include the following:

Communication capabilities: These allow communication interfaces to transmit data to centralized monitoring systems or control rooms.
Diagnostic systems: These can detect anomalies, predict potential failures, and recommend maintenance actions to prevent downtime and optimize performance.
Embedded sensors: These continuously monitor environmental conditions and connector performance, providing real-time data for analysis.
Fault detection and analysis: These can identify the root cause of faults and provide insights into potential corrective actions, helping to prevent costly equipment failures.
Remote control and management: These allow operators to remotely activate, deactivate, or adjust connector settings as needed, enhancing operational flexibility.

6. Interoperability and Standardization

Standardization efforts within the industry aim to improve interoperability between companies’ connectors and ensure compatibility across various systems and applications. Innovations in connector design and interfaces enable plug-and-play integration, simplifying system design and reducing integration costs for end-users.

7. Modular Designs

Modular high-voltage connectors are intended to adapt to varying voltage levels, current capacity, and environmental conditions. They facilitate installation, maintenance, and upgrades, lowering downtime and costs associated with system changes. Furthermore, these devices improve scalability, which enables users to easily expand or reconfigure their electrical systems as needed.

8. Multi-Contact Systems

Traditional single-point connectors are being replaced by multi-contact systems capable of transmitting multiple signals or power lines through a single connector interface. These connectors offer higher density, reduced footprint, and simplified wiring, making them ideal for applications where space is limited. They also apply in settings where multiple connections must be made efficiently.

Choose Connectronics Corp. for High-Quality Electrical Connectors

At Connectronics Corp., we are committed to providing our valued customers with exceptional quality and dependable electrical connectors! We follow strict quality control measures from initial design concepts to final production. This ensures that our products meet and exceed the most rigorous industry standards.

Posted by wpengine on August 31, 2020 8:06 pm | Leave a Comment

High voltage connectors are required in a broad range of industries, including aerospace, nuclear, defense, energy, medical, and many other fields. Design engineers must consider the environment and intended purpose where the connectors will operate to maximize safety, longevity, performance, and reliability while minimizing the chances of insulator failure. The types of materials the connector will be exposed to also plays a role in determining the system’s design.

Types of High-Voltage Connectors

The type of electrical connector that’s needed depends on the intended application. Based on the component’s intended function and environment, the connector can be equipped with either a shielded or unshielded cable. Shielded cables prevent electromagnetic interference and protect the cable against voltage surges; they’re usually used if the cable has solid insulation. Unshielded cables, on the other hand, are typically used for network cabling.

Other features can also be added or modified to suit the user’s needs. Here’s a brief overview of different types of high-voltage connectors available:

Single-Pin High-Voltage Connectors: This type of connector is constructed with a single pin and socket pair and can be combined to include different locking systems.
Multi-Pin High-Voltage Connectors: As its name suggests, a multi-pin connector uses multiple pins and sockets in its construction. Each application will dictate the required number of pins.
High-Voltage Connectors for Extreme Environments: Extreme environments require a high-voltage connector design that accommodates temperatures between -55° C and 150° C and elevations up to 70,000 ft.
Corona Resistant or Resistant High-Voltage Connectors: When the air around an electronically charged conductor becomes ionized, it causes corona discharge, which can degrade insulators over time. Corona Resistant connectors are placed at safe distances between disparate voltages to minimize degradation. They’re made with a dialectic material, have no sharp edges, and attach tightly to cables.
In-Line High-Voltage Connectors: Using male and female connectors, two high-voltage cables are joined with high-voltage connectors to function as one cable for signal continuity.
Panel Mount High-Voltage Connectors: When a connector must be fastened against or through a hole in a panel, it can be positioned on a mounting board behind the panel or with a thread and nut fastener. Technicians can use a free-hanging rectangular panel mount, circular connectors, or circular connector housings.

High-Voltage Connector Design Considerations

High voltages place extreme stress on all device components, which presents certain challenges. An energy surge can cause catastrophic failure in connections that would otherwise function adequately with a lower voltage.

Corona Discharge

When the electrical field around a conductor reaches 300 V. or higher and becomes conductive, but isn’t high enough to cause arcing, it creates corona discharge. If there are gaps or voids inside dielectric connectors, the air can also ionize and contribute to corona discharge. Over an extended period, corona discharge will cause dielectric breakdown.

Arcing

An electrical breakdown of gas through normally nonconductive mediums (including the air) is called arcing. Arcing produces an ongoing plasma discharge that can be destructive: The electrical current can produce carbon-filled voids, making the dielectric unable to withstand high voltages.

High-Voltage Clearance and High-Voltage Creepage

Separation within specified distances is vital to maintain efficacy and safety in high-voltage connections. These critical distances are called clearance or creepage and will vary according to safety specifications for each application.

High-voltage connectors protect electronic devices and ensure safe operation, but designing and manufacturing these products requires considerable care. Depending on your project and its environment, an engineer can help you select features, such as shielded or unshielded cables, and determine how many pins to include in the connectors. They can also help you select a mounting method and answer any questions you have about operating your equipment safely.

Turn to Connectronics for Specialty High Voltage Connectors

When high-voltage connectors are required, you need an electrical parts manufacturer that has the experience and technology you can depend on. Connectronics Corp. has over 30 years of experience manufacturing custom connectors and interconnection systems and is AS9100D-certified with an ISO9000:2015 management system. Contact us for more information about our connectors and cable services or request a quote today.

Aerospace Connectors: Connecting the Skies With Reliability