Military Aviation Wave Switch KB5C11W4D20P

Product Overview

The KB5C11W4D20P is a specialized Military Wave Switch engineered for reliable operation in high-vibration environments found in drone systems, aircraft engines, train controls, and Aviation Electronics. Featuring a unique wave-form actuation mechanism, this switch is specifically designed to maintain electrical integrity and mechanical reliability under continuous vibration and shock conditions. As an advanced component in YM's comprehensive aviation solutions portfolio—complementing products like Military Aviation Band Switches and Aviation Button Switches—the KB5C11W4D20P delivers dependable performance where traditional switches might fail due to mechanical stress.

 

Technical Specifications

• Model Number: KB5C11W4D20P
• Switch Type: Military-grade wave-form vibration-resistant switch
• Actuation Mechanism: Wave-form mechanical design for vibration resistance
• Electrical Ratings: 1A at 28V DC resistive load
• Coil Power Consumption: (0.3 - 0.43) Watts
• Electrical Life: Minimum 100,000 switching operations
• Low-Level Signal Capability: (10-50) μA at (10-50) mV for sensitive control circuits
• Contact Resistance: Initial ≤50mΩ; After durability testing ≤200mΩ
• Switching Speed: Action time ≤4ms; Release time ≤4ms; Incentive pulse width (10-50) ms
• Vibration Resistance: Specifically engineered for operation under continuous vibration up to 20G
• Shock Resistance: Withstands mechanical shock up to 100G
• Dielectric Strength: 500V RMS @ 50Hz (normal pressure); 250V RMS @ 50Hz (low pressure)
• Insulation Resistance: >500 MΩ initially; >50 MΩ after environmental testing
• Weight: Less than 3 grams
• Environmental Sealing: Maximum leakage rate ≤ 1.0 x 10⁻³ Pa·cm³/s
• Operating Temperature: Performance validated for extreme aviation conditions, compatible with Aviation Temperature Sensor ranges
• Actuation Force: Optimized for reliable operation in high-vibration environments

Product Features & Competitive Advantages

1. Wave-Form Vibration Resistance: Unique mechanical design incorporates wave-form elements that dampen vibration effects, preventing accidental actuation or contact bounce in high-vibration environments—similar to vibration management in Military Electronic Horn systems.
2. Military-Grade Environmental Protection: Advanced hermetic sealing (≤10⁻³ Pa·cm³/s) provides comprehensive protection against moisture, dust, and corrosive elements while maintaining vibration resistance, matching the sealing standards of Aviation Oil Sealed Valves.
3. Shock-Resistant Construction: Reinforced internal components and mounting system withstand mechanical shock up to 100G, ensuring reliability in impact-prone applications.
4. Anti-Vibration Contact Design: Special contact geometry and spring mechanisms prevent contact separation or bounce during continuous vibration, maintaining circuit integrity.
5. Thermal Stability: Engineered to maintain consistent performance across wide temperature ranges encountered in aerospace applications.
6. Reduced Contact Bounce: Wave-form mechanism minimizes contact bounce during switching transitions, providing cleaner signal transitions for sensitive control systems.
7. Compact Vibration-Tolerant Design: Maintains small footprint while incorporating vibration-dampening features, enabling use in space-constrained high-vibration applications.

Installation and Integration Procedure

1. Vibration Analysis: Assess installation environment vibration profile to ensure compatibility with switch specifications.
2. Mounting Surface Preparation: Ensure mounting surface is rigid and properly prepared to minimize transmitted vibration.
3. Secure Installation: Mount switch using provided vibration-resistant hardware, applying proper torque to maintain sealing while avoiding over-tightening.
4. Vibration-Isolated Wiring: Use flexible wiring or vibration-resistant cable management to prevent stress on electrical connections.
5. Sealing Verification: Confirm environmental seals are properly engaged to maintain protection in vibrating environments.
6. Vibration Testing: Test switch operation under simulated vibration conditions to verify performance before full system integration.
7. System Integration Testing: Verify operation with connected systems like Hydraulic Circuit Breakers or Aviation Pressure Sensors under vibration conditions.

Application Scenarios

The KB5C11W4D20P Military Wave Switch is specifically engineered for applications subject to continuous vibration and mechanical shock:

• Aircraft Engine Controls: Switches mounted directly on or near aircraft engines, auxiliary power units, and propulsion systems.
• UAV Vibration-Prone Locations: Control switches in drone fuselages near propulsion systems and in high-vibration payload areas.
• Rail Vehicle Under-Carriage Controls: Switches mounted on train under-carriages, bogies, and vibration-intensive mechanical systems.
• Military Vehicle Tactical Systems: Control switches in armored vehicles, tactical equipment, and mobile systems subject to rough terrain vibration.
• Industrial Vibration Environments: Machinery controls, processing equipment switches, and automation controls in high-vibration manufacturing environments.
• Test and Measurement on Moving Platforms: Control switches for test equipment mounted on moving vehicles, aircraft, or vibration test fixtures.
• Marine and Offshore Equipment: Switches on marine vessels, offshore platforms, and equipment subject to wave-induced vibration.
• Ground Support Equipment: Controls for aircraft ground power units, tow tractors, and maintenance equipment with inherent vibration.

Value Proposition for Vibration-Intensive Applications

• Enhanced Reliability in Harsh Environments: Specifically designed to overcome the primary failure mode (vibration-induced failure) in demanding aerospace and industrial applications.
• Reduced Maintenance Requirements: Vibration-resistant design decreases failure frequency and associated maintenance costs in high-vibration installations.
• Improved System Uptime: Minimizes unplanned downtime caused by vibration-induced switch failures in critical control systems.
• Longer Service Life: Wave-form mechanism reduces mechanical wear from continuous vibration, extending operational life compared to standard switches.
• Signal Integrity Maintenance: Prevents contact bounce and intermittent connections that can cause erroneous signals in sensitive control systems.
• Cost-Effective Vibration Solution: Provides specialized vibration resistance at competitive cost points compared to custom vibration-dampening solutions.

Certifications & Compliance

The KB5C11W4D20P Military Wave Switch is designed and manufactured to meet or exceed performance requirements of international standards relevant to vibration-resistant components, including military specifications for vibration and shock resistance (MIL-STD-810 considerations), aviation vibration requirements, and industrial vibration standards. Our manufacturing processes comply with stringent quality management systems specifically addressing vibration performance validation, and we provide comprehensive technical documentation including vibration test data to support customer qualification, certification, and compliance efforts for vibration-intensive applications.

Customization & OEM/ODM Services

YM offers specialized customization options for the KB5C11W4D20P wave switch series for specific vibration environments:

• Custom vibration resistance specifications for specific frequency ranges and amplitude profiles
• Special mounting configurations for unique vibration isolation requirements
• Custom actuation mechanisms optimized for specific vibration characteristics
• Enhanced sealing for vibration environments with additional contaminant exposure
• Special electrical ratings for vibration-intensive applications
• Custom contact materials and geometries for improved vibration performance
• Application-specific vibration testing and validation protocols
• Integration with complementary vibration-resistant components like Solid State Relays

Our demonstrated OEM and ODM expertise in specialized switching components, proven across our Automotive Relay and Industrial Power Relay product lines, ensures we can develop tailored wave switch solutions that precisely match your vibration environment requirements and application specifications.

Production Process & Vibration Validation

1. Specialized Component Manufacturing: Precision manufacturing of wave-form mechanical elements and vibration-resistant components.
2. Vibration-Optimized Assembly: Careful assembly techniques that maintain vibration resistance throughout the manufacturing process.
3. Contact System Engineering: Special contact designs and materials selected specifically for vibration resistance and reduced contact bounce.
4. Vibration Testing During Production: Sample units undergo vibration testing at multiple production stages to ensure consistent performance.
5. Comprehensive Electrical Testing: 100% testing includes contact resistance, switching timing, dielectric strength, and insulation resistance.
6. Vibration Performance Validation: Extensive vibration testing on production samples to verify performance across specified vibration profiles.
7. Shock Resistance Testing: Mechanical shock testing to validate performance under impact conditions.
8. Final Quality Assurance: Comprehensive inspection including dimensional verification, mechanical function testing, electrical performance validation, vibration resistance confirmation, and complete manufacturing traceability.

System Integration and Complementary Vibration Solutions

The KB5C11W4D20P Military Wave Switch is designed for integration into systems subject to continuous vibration and mechanical shock. For enhanced vibration performance in complete systems, consider pairing with YM's complementary products such as Aviation Rocker Switches with vibration-resistant variants, Military Aviation Band Switches designed for harsh environments, and Aviation Copper Fuse Holders with vibration-resistant features. This comprehensive approach enables the creation of reliable control systems for aerospace, defense, and industrial applications where vibration resistance is critical for operational reliability and system longevity.