High-Density D-Sub Connector for Harsh Environments
Product Overview
The YM Military Aviation Connector Y3AII-1832ZK10 is a ruggedized, high-density D-Sub connector engineered for reliable signal transmission in demanding aerospace, defense, and industrial applications. This enhanced connector variant is specifically designed for integration with Aviation Microswitch systems, Military Aviation Encoding switch interfaces, and drone flight control units where environmental protection is critical. As part of YM's comprehensive aviation component portfolio—which includes complementary products like Aviation Temperature Sensor and Aviation Hours Timer—the Y3AII-1832ZK10 delivers exceptional performance in harsh conditions while maintaining the familiar D-Sub form factor for easy integration.
Core Advantage: Military-grade environmental protection combined with high-density D-Sub configuration, providing reliable interconnection where standard commercial D-Sub connectors would fail in harsh operating conditions.
Technical Specifications
- Model: Y3AII-1832ZK10
- Connector Type: High-Density D-Sub, Ruggedized Metal Shell
- Physical Characteristics:
- Shell Size: Standard D-Sub footprint (DB9, DB15, DB25, DB37, or DB50 configurations)
- Material: Steel or aluminum alloy with corrosion-resistant plating
- Mounting: Panel mount with integrated flange and hardware
- Weight: 20-50 grams (depending on shell size and configuration)
- Contact System:
- Contact Configuration: High-density D-Sub arrangement
- Contact Types: Machined contacts with gold plating over nickel barrier
- Contact Positions: 9, 15, 25, 37, or 50 positions (standard options)
- Current Rating: 5A per contact (signal/power applications)
- Contact Resistance: ≤10mΩ initial (military-grade specification)
- Insertion/Extraction Force: Optimized for reliable mating cycles
- Electrical Performance:
- Voltage Rating: 500V AC/DC at sea level
- Insulation Resistance: >5,000 MΩ at 500V DC
- Dielectric Strength: 1500V RMS for 60 seconds
- EMI/RFI Shielding: >90dB effectiveness (30MHz-1GHz)
- Frequency Response: DC to 500MHz (signal integrity maintained)
- Environmental & Mechanical:
- Ingress Protection: IP67 (submersible to 1 meter for 30 minutes)
- Operating Temperature: -55°C to +125°C
- Sealing System: Multi-point silicone sealing with compression design
- Vibration Resistance: 10-2000Hz, 15G (MIL-STD-1344, Method 2007)
- Shock Resistance: 75G, 11ms duration
- Coupling Mechanism: Four-corner screw lock with anti-vibration features
- Mating Cycles: 500 cycles minimum
- Salt Spray Resistance: 500 hours minimum per MIL-STD-202
Product Features & Advantages
- Military-Grade Environmental Sealing: Advanced multi-point sealing system provides complete protection against moisture, dust, fuels, and hydraulic fluids, specifically designed for integration with Aviation Oxygen Valve and Aviation Oil Sealed Valve systems in harsh environments.
- High-Density Configuration with Standard Footprint: Maintains familiar D-Sub form factor while providing enhanced performance, enabling easy integration with existing Aviation Button Switch and Aviation Rocker Switch control panels.
- Superior EMI/RFI Protection: Enhanced metal shell design with continuous grounding provides excellent electromagnetic compatibility when connecting to sensitive equipment like Military Electronic Horn and Aviation Press Meter systems.
- Ruggedized Construction: Reinforced shell, robust mounting hardware, and vibration-resistant locking mechanism ensure reliable performance in demanding applications including integration with Military Aviation Encoding switch and sensor systems.
- Corrosion-Resistant Materials: Military-specification plating and finishes provide excellent resistance to salt spray, chemicals, and environmental corrosion for extended service life in challenging conditions.
- Field-Serviceable Design: Removable contacts and accessible hardware enable field maintenance and repair, reducing downtime and maintenance costs in critical applications.
Our Manufacturing Advantage: YM leverages advanced manufacturing technologies developed through producing Military Aviation connector systems and Aviation Microswitch components, enabling precise fabrication of ruggedized D-Sub connectors with enhanced environmental protection features.
How to Integrate the Y3AII-1832ZK10 Connector
- Application Requirements Analysis: Assess environmental conditions and electrical requirements. This connector is specifically recommended for harsh environments involving Aviation Temperature Sensor systems or Aviation Haulage Pressure Sensor installations.
- Configuration Selection: Select appropriate shell size and contact count based on signal requirements. Consider compatibility with existing Military aircraft Plug and socket systems.
- Panel Design and Mounting: Design panel layout with proper clearance for connector installation and cable routing. Ensure adequate space for mating/unmating operations.
- Precision Assembly Procedures: Use calibrated crimping tools for contact termination. Follow specific torque values for mounting hardware and coupling screws to ensure environmental sealing integrity.
- System Integration and Testing: Connect to complementary systems like Aviation Cold Air Solenoid Valve controls or Hydraulic Circuit Breaker monitoring circuits. Perform comprehensive electrical, mechanical, and environmental validation testing.
Application Scenarios
The Y3AII-1832ZK10 enables reliable interconnection in demanding aviation and industrial applications:
- Aircraft Avionics Systems: Interfaces between flight control computers, navigation systems, and cockpit displays in environments exposed to moisture, vibration, and temperature extremes.
- Drone Ground Control Stations: Provides robust connections in portable ground control equipment interfacing with Military Aviation Band Switch controls and telemetry systems in field conditions.
- Railway Control and Signaling: Used in trackside control cabinets and onboard train control systems requiring reliable connections in harsh outdoor environments.
- Industrial Automation: Provides reliable connections in factory automation, robotic systems, and processing equipment exposed to washdown, chemicals, or outdoor conditions.
- Military Communications Equipment: Interfaces in field-deployable communication systems, radar equipment, and electronic warfare systems requiring rugged, reliable connections.
- Ground Support and Test Equipment: Used in portable test equipment for Aviation Copper Fuse Holder systems, Aviation Ammeter calibration, and Aviation Single Hydraulic Valve diagnostics in challenging field conditions.
Value for Buyers: Provides reliable performance in harsh environmental conditions, reduces system failures and maintenance costs, offers easy integration with standard D-Sub compatible equipment, ensures long-term durability in critical applications, and provides field-serviceability for reduced lifecycle costs.
Certifications & Compliance
Manufactured in our SGS-audited, ISO 9001:2015 certified facility, the Y3AII-1832ZK10 meets MIL-DTL-24308 specifications for D-Sub connectors with additional ruggedization features. Our production processes ensure full compliance with RoHS, REACH, and industry-specific material requirements. We support comprehensive qualification testing and provide project-specific certifications (UL, CE, MIL-qualification) as needed, maintaining standards consistent with our production of other aviation components like Aviation Oxygen Valve and Military Aviastion Temperature Sensor systems.
Customization Options
YM provides extensive customization capabilities for the Y3AII-1832ZK10 to meet specific application requirements:
- Custom Contact Configurations: Design specialized contact arrangements for specific applications involving Aviation Microswitch arrays or mixed signal configurations.
- Enhanced Environmental Protection: Additional sealing options, specialized materials, or protective coatings for extreme environmental conditions beyond standard specifications.
- Special Shell Modifications: Custom shell designs, mounting configurations, or integrated strain relief features for unique installation requirements.
- Specialized Material Options: Stainless steel shells, specialized platings, or high-temperature materials for specific corrosion resistance or thermal requirements.
- Integrated Accessory Solutions: Pre-assembled connector systems with integrated backshells, cable clamps, or protective covers.
- Identification and Labeling: Custom laser marking, color coding, or labeling for specific identification requirements in complex systems.
Our proven OEM/ODM expertise with aviation components, including Aviation Button Switch and Military Aviation Encoding switch systems, enables us to provide tailored connector solutions for your specific application requirements.
Production & Quality Assurance
Every Y3AII-1832ZK10 connector undergoes rigorous manufacturing and validation processes:
- Precision Manufacturing Processes: Components produced using CNC machining and precision stamping with tight tolerances for reliable mating and sealing performance.
- Enhanced Surface Treatments: Specialized plating and finishing processes including zinc-nickel or cadmium plating for corrosion resistance and environmental protection.
- Quality Material Selection: Use of certified materials meeting aerospace and military specifications for reliability in demanding applications.
- Precision Assembly: Controlled assembly processes ensuring proper alignment, sealing, and mechanical integrity with 100% visual inspection.
- Comprehensive Testing: Electrical testing including continuity, insulation resistance, and dielectric strength verification, plus environmental testing for sealing and durability.
- Enhanced Performance Validation: Sample testing for vibration, shock, salt spray, and thermal cycling to validate performance in harsh conditions.
- Traceability and Documentation: Full material and process traceability with comprehensive documentation for quality assurance and regulatory compliance.
This comprehensive quality assurance program ensures connectors meet the high standards required for integration with other precision aviation components like Aviation Hours Timer and Aviation Haulage Pressure Sensor systems, delivering reliable performance in demanding applications.
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