Bayonet-Coupled Reliability for Demanding Environments
Product Overview
The Military Aviation Connector J599 Series 26KD18SN is a high-reliability interconnect solution designed to meet the stringent demands of military and aerospace applications. As a key member of the esteemed J599 family, this connector exemplifies aviation connector with military grade quality, offering robust performance in extreme operational conditions. Featuring a reliable bayonet coupling mechanism (denoted by "KD"), it is engineered for quick, secure mating and exceptional vibration resistance. This military connector for aviation use provides a dependable interface for critical power and signal transmission, ensuring system integrity where performance cannot be compromised.
Product Features & Advantages
The J599 26KD18SN delivers superior performance through its purpose-built design and precision manufacturing:
- Robust Bayonet Coupling (KD): The quick-disconnect bayonet mechanism provides secure, vibration-proof mating with a positive lock, ideal for applications requiring frequent connection/disconnection under challenging conditions—a defining feature of this aviation type military spec connector plug.
- Exceptional Environmental Sealing: Incorporates advanced sealing systems that protect against moisture, dust, sand, and fluids, maintaining performance integrity from sea level to high-altitude, low-pressure environments.
- High-Reliability Contact System: Utilizes precision aviation grade terminals with gold plating on critical surfaces, ensuring low contact resistance, excellent conductivity, and longevity over 100,000 mating cycles.
- Superior Electrical Performance: Offers high dielectric strength and insulation resistance, preventing leakage and ensuring signal integrity in complex aerospace electrical connectors networks, far surpassing typical general aviation plugs.
- Durable & Lightweight Construction: Manufactured from high-strength, lightweight materials, achieving a total weight of less than 3 grams without sacrificing the mechanical ruggedness required for a military aviation plug.
- Standardized Compatibility: As part of the J599 series, it ensures intermutable with other compliant connectors of the same shell size and coupling type, simplifying logistics, maintenance, and system upgrades.
Manufactured under strict army aviation quality control regulations, this connector meets exacting military connector specifications for performance and reliability.
Technical Specifications
The performance parameters of the J599 26KD18SN are defined by precise, verifiable data:
- Series & Configuration: J599 Series, Shell Size 26, Bayonet Coupling (KD).
- Coil Power Consumption: 0.3 to 0.43 Watts.
- Contact Performance & Lifecycle:
- Rated Load: 1 Ampere at 28V DC, minimum 100,000 cycles.
- Low-Level Signal: Compatible with (10~50) μA at (10~50) mV signals for 100,000 cycles.
- Contact Resistance:
- Initial Maximum: ≤ 50 milliOhms per contact.
- Maximum Post-Life Test: ≤ 200 milliOhms per contact.
- Dynamic Timing Characteristics:
- Action Time: ≤ 4 milliseconds.
- Release Time: ≤ 4 milliseconds.
- Actuation Pulse Width: Adjustable from 10 to 50 milliseconds.
- Dielectric Withstanding Voltage:
- Standard Atmospheric Pressure: 500 Vr.m.s., 50Hz.
- Low Pressure (Altitude): 250 Vr.m.s., 50Hz.
- Insulation Resistance:
- Initial: > 500 MegaOhms.
- After Endurance Testing: > 50 MegaOhms.
- Weight: < 3 grams (complete connector assembly).
- Hermetic Sealing Performance: Maximum leakage rate ≤ 1 x 10-3 Pa·cm³/s.
- Electrical Coil Specifications: All ratings are referenced at 25°C ambient temperature.
Application Scenarios
The J599 26KD18SN's combination of ruggedness, sealing, and quick-disconnect capability makes it ideal for diverse demanding applications:
- Aircraft External Stores & Pylons: Quick-connect interfaces for weapons, fuel tanks, and sensor pods on wing and fuselage hardpoints.
- Ground Support Equipment (GSE): Connections for power carts, test sets, and diagnostic equipment servicing military aircraft, where rapid connection to multiple aircraft is required.
- Avionics & Cabin Systems: Reliable interconnections within navigation units, communication racks, and in-flight entertainment systems in military transport aircraft.
- Engine & APU Interfaces: Bayonet-coupled connections for engine monitoring sensors, starter systems, and auxiliary power unit controls.
- Portable Military Equipment: Used in man-portable radar, communication systems, and electronic warfare equipment where robust, quick-connect interfaces are essential.
Implementing this connector enhances operational efficiency through quick connect/disconnect, reduces maintenance time, and increases system reliability in harsh environments.
Installation and Mating Procedure
Proper handling ensures the longevity and reliability of this bayonet-style military type connector:
- Pre-Mating Inspection: Visually inspect the aviation connector plug and mating military Aviation Socket for damage, contamination, or bent pins. Ensure the bayonet lugs are clean.
- Alignment: Align the plug's key with the socket's keyway. Align the bayonet lugs with their corresponding slots in the coupling nut.
- Initial Insertion: Push the connector straight into the socket until the faces are nearly flush.
- Bayonet Locking: While holding the connector body, rotate the coupling nut clockwise approximately a quarter-turn until a positive stop and/or audible click is felt, indicating full engagement and lock.
- Verification & Strain Relief: Gently pull on the connector to confirm it is locked. Ensure the cable harness is properly clamped and strain-relieved to prevent stress on the connector backshell and internal aviation connector soldering points.
Certifications & Compliance
The J599 26KD18SN is designed and manufactured to conform to the performance requirements of relevant military specifications, including those associated with the J599 (MIL-DTL-38999) series. Our production is governed by a comprehensive quality management system aligned with international aerospace standards and the principles of army aviation quality control regulations, ensuring each connector delivers consistent, reliable performance.
Customization Options
We offer tailored modifications to the standard J599 26KD18SN platform to meet specific application needs:
- Contact Configuration: Custom pin layouts, selective contact population, and mixing of contact types (signal, power, filtered, coaxial) within shell size 26.
- Material & Finish Options: Special shell platings (cadmium, zinc-nickel), colored identification bands, and alternative elastomer compounds for extended temperature or fluid resistance.
- Backshell & Accessories: Various backshell styles (straight, 45°, 90°), materials, and protective dust caps specifically designed for the bayonet coupling.
- Cable Assembly Services: Complete custom cable harnesses with defined lengths, shielding, jacketing, and integration of other connector types, supported by detailed documentation like 5 pin aviation connector wiring diagrams for subsystem interfaces.
- Identification & Labeling: Custom laser marking with part numbers, serial numbers, logos, or client-specific identifiers.
Production Process & Quality Assurance
Every J599 26KD18SN connector is produced through a controlled, traceable manufacturing process. From precision machining of shell components and bayonet coupling parts to the automated assembly of aviation grade terminals and inserts, quality is embedded at each stage. Our rigorous QA includes 100% electrical testing (contact resistance, insulation resistance, dielectric withstand), dimensional verification, and sample-based environmental testing (vibration, shock, thermal cycling, salt spray). This ensures every connector meets the high-reliability standards expected of aviation grade connectors in defense applications.
Frequently Asked Questions (FAQ)
- Q: What is the key benefit of the bayonet ("KD") coupling compared to other styles?
A: The bayonet coupling offers extremely fast connect/disconnect (typically a quarter-turn), high resistance to vibration-induced loosening, and a very positive, tactile lock confirmation. It is ideal for applications requiring frequent mating/unmating or where tool access is limited. - Q: Is this connector intermutable with other J599 series bayonet connectors of different shell sizes?
A: Intermutability is generally limited to connectors within the same shell size (26) and coupling series (KD) to ensure proper mechanical and electrical alignment. It will not mate with smaller shell sizes like those used for 7 pin aviation connector or 8 pin military connector variants of different series. - Q: Can the connector withstand exposure to hydraulic fluids, jet fuels, and cleaning solvents?
A: Yes, when configured with appropriate elastomer seals and shell finishes, the J599 26KD18SN is designed to resist degradation from common aerospace fluids such as Skydrol, Jet A, and standard cleaning agents. Specific fluid compatibility details are available upon request. - Q: What tools are required for contact insertion/removal in this connector?
A> Standard contact insertion/removal tools specific to the contact size and series are required. We can supply the appropriate tooling kits for field service and repair operations. - Q: How does the weight of this connector compare to similar civilian Aviation Connectors?
A> While lightweight (<3g), this connector is typically more robust than commercial general aviation plugs due to its metal shell, advanced sealing, and reinforced construction to meet military specs. The weight is optimized for strength and durability rather than minimized for basic commercial applications.
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