KA1 Dual-Rating Aviation Switch -
Flexible 2A-250V / 4A-125V Power Management Solution
YM's KA1 Military Aviation Switch represents a breakthrough in versatile power switching with its innovative dual-rating capability, engineered specifically for aerospace, defense, and industrial applications requiring flexible power management. Rated for both 2A at 250V and 4A at 125V operation, this switch provides unprecedented design flexibility for drone electrical systems, aircraft engine controls, and aviation power distribution networks. Manufactured to the exacting standards of our Civil Metal Relay and Industrial Power Relay product lines, the KA1 delivers reliable performance across multiple operating scenarios.
As a cornerstone of YM's comprehensive aviation component portfolio, this dual-rated switch integrates seamlessly with our extensive range of Aviation Connectors and Aviation Rocker Switches, offering engineers a sophisticated solution for diverse electrical system requirements.
Technical Specifications
Dual-Rating Electrical Characteristics
- Primary Operating Point: 2A continuous current at 250V AC/DC
- Secondary Operating Point: 4A continuous current at 125V AC/DC
- Coil Power Consumption: Efficient low-power operation between 0.3W and 0.43W
- Contact Load Capacity & Durability:
- Standard Performance: Baseline rating of 1A at 28V DC resistive with extended dual-rating capability
- Low-Level Signal Precision: Maintains accuracy for sensitive (10-50)μA at (10-50)mV signals
- Operational Lifecycle: Verified for minimum 1,000,000 cycles at specified rating conditions
- Contact Resistance: Superior conductivity with initial resistance ≤50mΩ per contact. After durability testing, resistance remains ≤200mΩ
- Switching Speed: Fast response with actuation time ≤4ms and release time ≤4ms for both rating conditions
- Dielectric Strength:
- Standard Atmospheric Pressure: 500V RMS at 50Hz withstand voltage
- Low-Pressure Conditions: 250V RMS at 50Hz rating for high-altitude operation
- Insulation Resistance: Excellent electrical isolation with >500MΩ initially and >50MΩ after accelerated lifecycle testing
Mechanical & Environmental Specifications
- Dual-Rating Engineering: Specifically designed to handle two distinct voltage-current combinations in a single compact package
- Weight: Ultra-lightweight construction under 3 grams for weight-critical aerospace and UAV applications
- Hermetic Sealing: Advanced environmental protection with maximum leakage rate ≤10⁻³ Pa·cm³/s. This Aviation Oil Sealed Valve-grade sealing ensures reliability in harsh conditions
- Control System Compatibility: Compatible with standard control signals, operating with incentive pulse widths from 10ms to 50ms
- Temperature Performance: Performance characterized at 25°C with validated operation across extended military temperature ranges
- Thermal Design: Optimized for efficient heat dissipation at both 2A/250V and 4A/125V operating points
Features & Competitive Advantages
- Innovative Dual-Rating Design: Unique capability to operate reliably at both 2A-250V and 4A-125V, providing unmatched flexibility for varying power system requirements
- Civil-Grade Durability: Incorporates rugged construction principles from our Civil Electronic Horn and Military Pressure Sensor manufacturing processes
- Optimized Contact Architecture: Special contact geometry and materials engineered to handle both higher voltage arc suppression (250V) and higher current thermal management (4A)
- True Hermetic Sealing Technology: Utilizes proprietary sealing methods derived from our Metal Sealing Relay production for superior environmental protection
- Enhanced Arc Management: Advanced contact design minimizes arcing during switching operations at both 250V and 125V ratings
- Intelligent Thermal Performance: Engineered to dissipate heat effectively across both operating scenarios, ensuring consistent performance and extended lifespan
- Universal Application Compatibility: Eliminates the need for multiple switch types in systems with mixed voltage/current requirements, simplifying design and inventory
- Streamlined Integration: Designed for easy installation and connection, compatible with standard PCB Board Relay layouts and wiring systems
Installation & System Integration Guidelines
- Operating Point Analysis: Determine which specific rating combination (2A/250V or 4A/125V) aligns with your circuit's actual operating parameters
- Rating Validation: Confirm the selected operating conditions fall within the switch's specified dual-rating capabilities
- Thermal Planning: Ensure adequate heat dissipation provisions, particularly when operating at the higher current 4A rating
- Secure Mounting Installation: Mount the switch securely using appropriate hardware, avoiding mechanical stress on the switch housing
- Proper Electrical Connection: Use appropriately sized conductors for the selected current rating, considering both potential operating scenarios
- Environmental Protection Verification: Confirm integrity of surrounding environmental seals if installed in exposed locations
- Pre-Operational Testing: Test at the intended operating point, verifying switching performance, contact resistance, and thermal behavior
- Complete System Validation: Integrate into the final system architecture and perform comprehensive testing under actual operating conditions
Application Scenarios & Business Value
Primary Application Domains
- UAV Power Management Systems: Flexible power switching in drone systems where different subsystems operate at varying voltage-current combinations
- Aircraft Electrical Distribution: Power control in aircraft featuring mixed voltage systems (e.g., 125VAC and 250VAC circuits within the same platform)
- Avionics Equipment Control: Switching for instruments and systems with diverse power requirements in cockpit and equipment bay installations
- Ground Support & Test Equipment: Versatile switching solution for maintenance and testing equipment handling multiple power standards
- Industrial Power Control Panels: Machinery and control systems requiring switching capability across different electrical load profiles
Value Proposition for Engineering & Procurement
- Inventory Optimization: Single component serving multiple rating requirements significantly reduces inventory complexity and part number management
- Design Standardization: Enables use of identical switches across different circuit types within complex systems, simplifying design and documentation
- Cost Reduction: Reduced need for multiple specialized switches lowers overall component costs and simplifies procurement processes
- Enhanced System Reliability: Military-grade construction and dual-rating validation ensure dependable performance across varied operating conditions
- Supply Chain Simplification: Fewer unique part numbers streamline procurement, inventory management, and production planning activities
- Maintenance Efficiency: Standardization on fewer switch types simplifies field maintenance procedures and spare parts inventory requirements
- Development Acceleration: Design reuse capability across different circuit applications speeds development cycles and reduces validation testing
Manufacturing Process & Quality Assurance
The KA1 dual-rated switch undergoes specialized manufacturing and testing processes to ensure performance across both rating specifications.
- Dual-Rating Component Engineering: Contacts and internal components specifically designed and manufactured for both 2A/250V and 4A/125V operation
- Precision Contact Fabrication: Advanced manufacturing processes create contacts optimized for both high-voltage arc management and high-current thermal performance
- Environmental Sealing Application: Hermetic sealing implemented using technology refined through Aviation Oil Sealed Valve production
- Comprehensive Dual-Point Testing: Each unit undergoes automated validation testing at BOTH rating conditions (2A/250V and 4A/125V) to ensure performance across the entire operating range
- Thermal Performance Validation: Specialized testing verifies proper heat dissipation characteristics at both higher voltage and higher current operating points
- Extended Lifecycle Testing: Accelerated durability testing conducted at both rating specifications to validate long-term performance
- Final Quality Certification: Complete dimensional, visual, and functional inspection before protective packaging with clear dual-rating identification
Compliance & Customization Services
Standards Compliance
The KA1 dual-rated switch is designed and manufactured to meet stringent performance requirements for aerospace, military, and industrial applications. Our comprehensive quality management system ensures compliance with relevant standards for both voltage and current rating specifications.
Customization Capabilities
YM offers extensive customization options for the KA1 series, leveraging our expertise with New Energy Relay and Automotive Relay systems:
- Custom Rating Combinations: Alternative dual-rating configurations tailored to specific application requirements
- Voltage-Current Profile Optimization: Modifications to optimize performance for particular voltage/current combinations
- Terminal Configuration Options: Custom terminal types, arrangements, or connection methods for specific mounting needs
- Thermal Management Enhancements: Specialized heat dissipation features for extreme operating environments
- Environmental Sealing Variations: Enhanced sealing configurations for specific contaminant protection requirements
- Application-Specific Validation Testing: Custom testing protocols designed to validate performance at specific operating conditions required by the application
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