Military Aviation Connector YB2TAX with CXY-2ZX Adapter |
Modular High-Density Interconnect System
Product Overview
The YM Military Aviation Connector system, comprising the YB2TAX circular connector and the CXY-2ZX adapter, is a modular, high-density interconnect solution engineered for complex wiring systems in aerospace, defense, and advanced industrial applications. This system provides a rugged, sealed interface for both power distribution and high-fidelity signal transmission, ideal for connecting drone flight control units, aircraft engine monitoring systems, and railway control cabinets. Designed to work in harmony with critical electronic components like Military Metal Relays and PCB Signal Relays, the YB2TAX+CXY-2ZX combination offers unparalleled flexibility, allowing for easy field reconfiguration, testing, and maintenance while maintaining full environmental protection.
Core Advantage: Modular adapter (CXY-2ZX) system that enables rapid interface conversion, circuit branching, or test point access without compromising the environmental seal or electrical integrity of the main YB2TAX connector.
Technical Specifications
- System Model: YB2TAX (Primary Circular Connector) + CXY-2ZX (Modular Adapter)
- Shell Characteristics:
- Material: Aluminum alloy with MIL-spec anodized or plated finish for corrosion resistance.
- Coupling: Bayonet or threaded coupling mechanism for vibration-proof mating.
- Shell Size: Compact design optimized for high-contact density in limited spaces.
- Contact System:
- Contact Types: Crimp, solder, or PCB mount contacts available. Gold-plated for low-level signal integrity.
- Contact Density: High pin count configuration to consolidate multiple wire connections into a single sealed interface.
- Current Rating: Mixed contacts supporting signals (≤5A) and power (up to 20A or more per contact).
- Contact Resistance: ≤10mΩ initial per contact to ensure minimal voltage drop.
- Electrical Performance:
- Voltage Rating: Rated for 250V AC/DC or higher, compatible with aircraft 28V DC systems and control circuits using Industrial Power Relays.
- Insulation Resistance: >1000 MΩ at 500V DC.
- Dielectric Strength: 1500V AC minimum between contacts and shell.
- Environmental & Mechanical:
- Ingress Protection (IP): IP67 standard with mated adapter; individual components are environmentally protected.
- Operating Temperature: -55°C to +125°C standard range.
- Sealing: Multiple silicone seals at all interfaces (wire, adapter, connector).
- Adapter Function (CXY-2ZX): Provides a sealed pass-through or conversion interface, often featuring additional port(s) for branching or test access.
Product Features & Advantages
- Modular Adapter System (CXY-2ZX): The key differentiator. This adapter allows for inline splicing, “Y” branching, or the addition of test ports without cutting into the main cable harness, dramatically simplifying system upgrades and diagnostics.
- High-Density Packaging: Maximizes the number of contacts within a minimal shell size, reducing overall system weight and footprint—critical in aviation and drone applications.
- Superior Sealed Integrity: Maintains full environmental sealing (IP67) even when the adapter is integrated, protecting connections from moisture, dust, and fluids as effectively as a Metal Sealing Relay protects its internal mechanism.
- Rapid Deployment & Reconfiguration: The bayonet coupling allows for quick mating/de-mating, while the adapter system enables field changes without specialized tooling or harness rework.
- EMI/RFI Shielding: Full metallic shell and optional shielded backshells provide excellent protection against electromagnetic interference, ensuring clean signal transmission to and from sensitive devices like Solid State Relays.
- Mixed Signal & Power Capability: Designed to carry both low-current control signals (for PCB Signal Relays) and moderate power within the same connector, simplifying cabinet and enclosure design.
Our Manufacturing Advantage: YM leverages its precision engineering expertise from manufacturing Polarized Relays and Latching Relays to achieve the exacting tolerances required for the multi-piece sealing surfaces and precision contacts in the YB2TAX+CXY-2ZX system, ensuring flawless performance and longevity.
How to Integrate the YB2TAX + CXY-2ZX Connector System
- System Architecture Planning: Determine the need for branching, testing, or interface conversion in your harness design. Plan the location for the CXY-2ZX adapter.
- Component Selection: Select the YB2TAX connector with the correct contact layout and the appropriate variant of the CXY-2ZX adapter (pass-through, “Y”, or test port).
- Harness Sub-Assembly: Terminate wires to the contacts and assemble them into the connector and adapter inserts. Use proper crimping tools and follow the pin-out diagram precisely.
- Sealing Assembly: Assemble all sealing grommets, O-rings, and backshells. Ensure seals are clean and properly seated before final tightening.
- System Integration & Test: Mate the connector and adapter, engaging the coupling mechanism until locked. Perform continuity, insulation resistance, and (if required) HIPOT tests on the complete assembly.
Application Scenarios
The modular YB2TAX+CXY-2ZX system is ideal for applications requiring reliable, sealed interconnections with built-in flexibility:
- Aircraft Engine & Avionics Bays: Connects engine sensor harnesses to the main avionics bus, with adapters used for adding test points for ground maintenance.
- Unmanned Aerial Vehicle (UAV) Payload Integration: Allows quick swapping of sensor pods (EO/IR, comms) on drones via a sealed adapter interface.
- Railway Vehicle Inter-Car Connections: Used in jumper cables between train cars, where adapters can facilitate circuit branching for different car configurations.
- Military Field-Deployable Systems: Enables rapid reconfiguration of communication or radar systems in the field using different adapter modules.
- Industrial Machinery with Modular Sections: Connects power and control between removable machine modules (e.g., printing heads, tool changers) in harsh factory environments.
- New Energy Power Conversion Cabinets: Provides sealed, high-density connections within inverter or New Energy Relay enclosures, with adapters for diagnostic access.
Value for Buyers: Reduces lifecycle costs by enabling easy field modifications and upgrades, minimizes system downtime through rapid testing and module replacement, consolidates wiring to reduce weight and complexity, and ensures long-term reliability in challenging environments.
Certifications & Compliance
Produced in our SGS-audited facility, the YB2TAX+CXY-2ZX system is designed to the performance standards of MIL-DTL-38999 and other relevant aerospace/industrial connector specifications. Our manufacturing process adheres to a certified quality management system, ensuring consistency and traceability. Material compliance (RoHS, REACH) is standard, and project-specific certifications (UL, CE) can be supported, aligning with our approach for other product lines like Automotive Relays.
Customization Options
YM offers extensive customization to tailor this connector system to your exact needs:
- Adapter Configuration (CXY-2ZX): Custom designs for specific branching ratios (1-in/2-out, etc.), integrated test ports with sealed caps, or special angular orientations.
- Contact Layout & Types: Fully customizable insert patterns with any mix of signal, power, high-voltage, or data contacts.
- Special Materials: Shells in stainless steel or composites, high-temperature seals (Viton), and custom contact platings.
- Integrated Wiring: Complete harness assembly service, including potting of the adapter junction for strain relief and extra environmental protection.
- Keying & Coding: Custom keying positions and color-coded shells to prevent mismating in complex systems.
- Labeling: Laser marking with custom part numbers, pin maps, or company logos.
Our deep OEM/ODM experience, proven in developing custom Flash Relays and specialized PCB Board Relays, is directly applicable to creating a perfect connector solution for your application.
Production & Quality Assurance Process
Every YB2TAX connector and CXY-2ZX adapter undergoes a stringent, multi-stage manufacturing and testing process:
- Precision CNC Machining: Shells and adapter bodies are machined from certified material blanks to exacting tolerances critical for sealing.
- Contact Fabrication & Plating: Contacts are stamped/formed and undergo selective gold or silver plating in controlled plating lines to ensure optimal conductivity and durability.
- Injection Molding of Insulators & Seals: Inserts, grommets, and sealing components are molded from qualified, high-performance elastomers and thermoplastics.
- Sub-Assembly & Inspection: Contacts are loaded into inserts. Each sub-assembly is visually and dimensionally inspected.
- Final Assembly & 100% Sealing Test: Complete units are assembled. A sample from every production batch undergoes rigorous IP67 immersion testing and dielectric testing.
- Electrical Testing & Traceability: All connectors and adapters are tested for continuity and insulation resistance. Full material and process traceability is maintained.
This comprehensive quality control, mirroring our processes for Solid State Relays and Latching Relays, guarantees a connector system built for absolute reliability.
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