Advanced High-Density Interconnect for Critical Systems
Product Overview
The Military Aviation Connector XC158-36F129Z1DP40 is an advanced, high-density interconnect solution engineered for the most demanding military and aerospace applications. This connector represents the forefront of aviation connector with military grade quality, designed to deliver exceptional reliability and performance in complex, data-intensive systems. With its sophisticated configuration and robust construction, it serves as a premium military connector for aviation use, providing secure, multi-channel interfaces for advanced avionics, sensor networks, and mission-critical electronics where signal integrity, density, and environmental resilience are paramount.
Product Features & Advantages
The XC158-36F129Z1DP40 offers superior performance through its advanced engineering and specialized design:
- Advanced High-Density Design: Engineered for maximum contact density in a compact form factor, ideal for consolidating numerous signal and power lines, significantly reducing space and weight compared to using multiple standard connectors like aviation connector 2 pin or 7 pin aviation connector assemblies.
- Sophisticated F-Series Coupling with Z1 Feature: Incorporates an advanced coupling mechanism ("F") with specialized "Z1" enhancements, likely indicating tool-assisted mating, enhanced locking, or specific polarization for foolproof connection in complex systems.
- Superior Environmental & Hermetic Sealing: Features multi-stage, high-integrity sealing technology providing exceptional protection against moisture, dust, fluids, and extreme pressure differentials, ensuring reliability from ground level to high-altitude operations.
- High-Performance Contact Array: Utilizes an array of precision aviation grade terminals with advanced materials and platings, ensuring ultra-low contact resistance, excellent signal integrity, and extended durability over 100,000 mating cycles.
- Enhanced Electrical Performance: Provides superior dielectric strength and high insulation resistance, critical for preventing crosstalk and ensuring signal fidelity in high-speed aerospace electrical connectors networks, far exceeding the capabilities of general aviation plugs.
- Optimized for Critical Applications: Designed from the ground up for mission-critical systems where failure is not an option, incorporating redundancy and reliability features at every design level.
This connector is a definitive example of an advanced aviation type military spec connector plug, manufactured under the most stringent controls that not only meet but often exceed the requirements of army aviation quality control regulations and detailed military connector specifications.
Technical Specifications
The XC158-36F129Z1DP40's performance is quantified by exacting parameters:
- Model Designation: XC158-36F129Z1DP40 Advanced Military Connector.
- Coil Power Consumption: 0.3 to 0.43 Watts operational range.
- Contact Performance & Durability:
- Standard Load Rating: 1 Ampere at 28V DC per contact, minimum 100,000 cycles.
- Low-Level Signal Capability: Compatible with (10~50) μA at (10~50) mV signals per contact for 100,000 cycles.
- Contact Resistance:
- Initial Maximum: ≤ 50 milliOhms per contact.
- Maximum After Life Testing: ≤ 200 milliOhms per contact.
- Dynamic Response Parameters:
- Action Time: ≤ 4 milliseconds.
- Release Time: ≤ 4 milliseconds.
- Actuation Pulse Width: Adjustable from 10 to 50 milliseconds.
- Dielectric Withstanding Voltage:
- Standard Pressure Conditions: 500 Vr.m.s., 50Hz.
- Low Pressure Conditions: 250 Vr.m.s., 50Hz.
- Insulation Resistance:
- Initial: > 500 MegaOhms between contacts.
- After Environmental Stress: > 50 MegaOhms between contacts.
- Weight: < 3 grams (optimized for high-density design).
- Hermetic Sealing Performance: Maximum leakage rate ≤ 1 x 10-3 Pa·cm³/s.
- Special Feature (Z1): Indicates a specific design enhancement such as tool-mating, unique keying, or enhanced shielding per customer specification.
Application Scenarios
This advanced connector is designed for next-generation military aerospace systems:
- Next-Generation Avionics Suites: High-speed data buses and power distribution within integrated core processors and mission computers for fighter aircraft and advanced platforms.
- Multi-Function Active Electronically Scanned Array (AESA) Radars: Dense interconnections between radar transmit/receive modules and central processors.
- High-Bandwidth Sensor Fusion Systems: Interfaces for EO/IR cameras, SIGINT payloads, and other sensors requiring massive data throughput in reconnaissance and targeting systems.
- Vehicle Management & Flight Control Systems: Critical data and power connections within fly-by-wire and vehicle health monitoring systems.
- Satellite & Spacecraft Payload Interfaces: High-reliability connectors for communication payloads and scientific instruments in space applications.
Implementing this advanced connector enables system architects to design more compact, capable, and reliable platforms by reducing interconnect complexity and improving signal integrity.
Installation and Operational Procedure
Due to its advanced nature, proper handling is crucial:
- System Integration Review: Carefully study the connector's interface requirements and the mating military Aviation Socket. Note any special Z1 feature requirements (e.g., specific tool).
- Precision Termination: Use high-precision tools for aviation connector soldering or crimping of the dense array of aviation grade terminals. Extreme care is needed to avoid damaging adjacent contacts.
- Connector Assembly: Follow a meticulous process to insert each contact into its designated cavity in the high-density insert. Use magnification if necessary.
- Specialized Mating: If the Z1 feature indicates tool-assisted mating, use the specified tool to ensure perfect alignment and engagement force. Engage the coupling mechanism until a definitive lock is confirmed.
- Comprehensive System Verification: Perform signal integrity tests (e.g., TDR for high-speed lines) in addition to standard continuity and insulation checks. Validate the function of any special Z1 features.
Certifications & Compliance
The XC158-36F129Z1DP40 is developed and manufactured under an advanced quality management system designed for cutting-edge Aerospace Components. Our processes and product validation are aligned with the most stringent requirements of relevant military standards and the principles of army aviation quality control regulations, often incorporating additional verification steps for high-reliability applications.
Customization Options
We offer deep customization for this advanced platform:
- Specialized Z1 Feature Configuration: Tailor the specific "Z1" enhancement (keying, tooling interface, shielding contact configuration) to your system's unique interface requirements.
- High-Speed Contact Optimization: Customize contact design and materials for specific impedance requirements (e.g., 50Ω, 75Ω) for RF or high-speed digital signals.
- Advanced Material Selection: Special alloys, composite materials, and platings for extreme environments, including radiation-hardened versions for space applications.
- Integrated Filtering & Conditioning: Incorporate filtered contacts, transient voltage suppressors, or integrated magnetics within the connector body.
- Full System Integration Support: Provide complete modeling data (3D CAD, signal integrity models), custom test fixtures, and co-engineering support for integration into your platform.
Production Process & Advanced Quality Assurance
Manufacturing the XC158-36F129Z1DP40 involves state-of-the-art processes. Precision machining creates complex geometries, while automated optical inspection (AOI) verifies every contact cavity. The assembly of high-density aviation grade terminals utilizes robotic precision. Our advanced QA includes 100% electrical testing with enhanced parameters (including crosstalk and insertion loss for critical circuits), 3D metrology for dimensional verification, and environmental testing that simulates the most extreme mission profiles. This ensures every military type connector meets the exceptional standards required for the most advanced aviation grade connectors.
Frequently Asked Questions (FAQ)
- Q: What does the "Z1" designation in the part number typically signify?
A> The "Z1" suffix usually indicates a specific variant or special feature set within the XC158-36F series. This could denote a unique keying pattern, a tool-mating requirement, a specific plating for enhanced corrosion resistance, or an integrated shielding feature. The exact specification is defined in the product's detailed technical data sheet. - Q: Is this connector suitable for high-speed digital or RF signals?
A> Yes, the XC158-36F129Z1DP40 platform can be configured for high-performance applications. With proper contact design (controlled impedance), material selection, and shielding, it can support high-speed data transmission and RF signals. Discuss your specific signal integrity requirements with our engineering team. - Q: What kind of tools are required for assembly and mating?
A> Given its high density and potential Z1 features, specialized tooling is typically required. This may include precision contact insertion/extraction tools, alignment fixtures, and possibly a specific mating tool. We supply or specify all necessary tooling for proper handling. - Q: How does this connector's density compare to standard military circular connectors?
A> It offers significantly higher contact density than standard circular connectors like the common 8 pin military connector. This allows for more functionality in a similar or smaller envelope, which is critical for modern, compact avionics packages. - Q: What is the lead time for such an advanced, customized connector?
A> Lead times are project-dependent. For standard configurations of this advanced series, we maintain planned production cycles. For fully customized orders involving the Z1 feature or other specials, we engage in a co-development process and provide a detailed project timeline after understanding all requirements.
Contact Now