High-Reliability Circular Connector System
Product Overview
The YM Military Aviation Connector series, models YB3TAX and YB3TPA, represents a high-performance, environmentally sealed circular connector system engineered for mission-critical electrical interconnections in aerospace, defense, and heavy industrial applications. Designed to withstand extreme vibration, moisture, and temperature fluctuations, these connectors ensure secure and reliable signal and power transmission for drone flight controllers, aircraft engine sensors, and train control systems. As part of YM's comprehensive interconnect and control solutions—which include precision components like Military Metal Relays and PCB Signal Relays—this connector series provides the robust physical interface required for systems where failure is not an option.
Core Advantage: Exceptional environmental sealing combined with a robust bayonet or threaded coupling mechanism, ensuring vibration-proof connections and IP67+/higher ingress protection for operation in harsh conditions.
Technical Specifications
- Model Series: YB3TAX (Plug), YB3TPA (Socket/Receptacle)
- Shell Material: High-Strength Aluminum Alloy with Corrosion-Resistant Finish (e.g., Cadmium or Zinc-Nickel Plating)
- Contact System:
- Contact Types: Pin and socket contacts, machined from copper alloy with gold or silver plating for optimal conductivity.
- Contact Sizes & Count: Configurable with various contact sizes (e.g., 16A, 20A, 40A) and pin counts to suit power, signal, and mixed applications.
- Contact Resistance: Extremely low initial contact resistance (typically ≤5mΩ per contact) to minimize voltage drop and heating.
- Electrical Performance:
- Voltage Rating: Rated for working voltages up to 600V AC/DC, suitable for aircraft systems and compatible with circuits using Industrial Power Relays.
- Current Rating: Per-contact ratings up to 40A or higher, capable of handling power distribution alongside control signals.
- Insulation Resistance: >1000 MΩ at 500V DC in standard conditions.
- Dielectric Withstanding Voltage: Typically 1500V AC minimum between contacts and shell.
- Mechanical & Environmental:
- Coupling Mechanism: Robust bayonet (quick-disconnect) or threaded coupling for secure mating and high vibration resistance.
- Ingress Protection (IP): Standard IP67 (dust-tight and waterproof up to 1m immersion). Higher levels (IP68/IP69K) available.
- Operating Temperature: -55°C to +125°C (or wider based on seal material).
- Vibration/Shock: Meets or exceeds MIL-DTL-38999 Series III or similar stringent specifications.
- Sealing: Multiple silicone rubber seals (interface, wire, and insert seals) ensure complete environmental isolation.
Product Features & Advantages
- True Military-Grade Construction: Designed and tested to meet rigorous military (MIL-SPEC) and aerospace standards for environmental and mechanical durability, perfectly complementing systems built with our Military Metal Relays.
- Superior Environmental Sealing: Multi-layer sealing system provides exceptional protection against moisture, dust, fuels, and hydraulic fluids, ensuring reliability in exposed or wash-down environments.
- High-Vibration Performance: The positive-lock coupling mechanism (bayonet or threaded) prevents accidental disconnection in high-vibration settings common in aviation, rail, and off-road vehicles.
- Modular & Configurable: Inserts can be customized with various combinations of power, signal, coaxial, or fiber optic contacts, offering design flexibility similar to our configurable PCB Board Relay options.
- EMI/RFI Shielding: The metal shell and optional shielded backshells provide excellent electromagnetic interference protection for sensitive signals, critical when connecting to Solid State Relays or avionics.
- Corrosion-Resistant Finish: Shells feature a durable, conductive finish that resists corrosion from salt spray and chemicals, extending service life.
Our Manufacturing Advantage: YM applies its 18+ years of precision metalworking and electrical contact expertise—gained from manufacturing Metal Sealing Relays and Polarized Relays—to the production of these connectors. This ensures superior contact plating, precise machining tolerances, and reliable sealing performance.
How to Specify and Install the YB3TAX/YB3TPA Connector
- Application Definition: Define the electrical requirements (voltage, current per contact, signal type), environmental conditions (IP rating, temperature, fluids), and mechanical needs (coupling type, cable strain relief).
- Configuration Selection: Select the shell size, contact layout (pin/socket arrangement), contact types (power/signal), and backshell style.
- Cable Preparation & Contact Crimping: Strip cables to specified length. Use the correct, calibrated tooling to crimp contacts onto wires. Insert contacts into the connector insert in the designated positions.
- Assembly & Sealing: Assemble the insert into the shell, ensuring all grommets, seals, and strain relief components are correctly positioned and torqued.
- Mating & System Check: Align the plug and socket keys, engage the coupling mechanism (bayonet or thread) until it clicks/locks securely. Perform continuity and insulation resistance tests on the mated assembly.
Application Scenarios
The YB3TAX/YB3TPA connector series is indispensable in harsh-environment interconnection applications:
- Manned & Unmanned Aircraft: Engine sensor harnesses, flight control system interfaces, wing-to-fuselage connections, and external pod/avionics connections.
- Ground Support & Test Equipment: Interfaces between ground power carts, test benches, and aircraft/vehicles.
- Railway & Mass Transit: Car-to-car jumpers, connections for traction systems, and outdoor control cabinet interfaces exposed to weather.
- Military Vehicles & Naval Systems: Powertrain, weapon system, and communication equipment connections in armored vehicles and ships.
- Industrial Automation & Robotics: Connections for outdoor robotic arms, mining equipment, and food & beverage processing machinery requiring wash-down protection.
- New Energy Infrastructure: Used in charging station connectors and power distribution units within New Energy Relay and battery system enclosures requiring robust outdoor performance.
Value for Buyers: Eliminates connection failures in critical systems, reduces maintenance downtime, protects sensitive electronics from environmental damage, simplifies field servicing with quick-disconnect capability, and ensures long-term system integrity.
Certifications & Compliance
Manufactured in our SGS-audited facility, the YB3 series connectors are designed to meet the performance requirements of key international standards, including MIL-DTL-38999 (or equivalent EN, DIN standards). While product-level certifications (e.g., UL, CE) are available based on project needs, our production adheres to the same rigorous quality management system applied to our certified Automotive Relay lines. Material compliance, such as RoHS and REACH, is standard.
Customization Options
YM offers extensive customization to tailor the connector to your exact system requirements:
- Contact Configuration: Fully customizable insert layouts with any mix of power, high-voltage, signal, coaxial, or fiber optic contacts.
- Shell Size & Style: Variations in shell size, keying positions, and coupling mechanism (bayonet, threaded, push-pull).
- Special Materials & Platings: Shell materials (stainless steel, composite), specialized platings for extreme corrosion resistance, and high-temperature seals.
- Integrated Backshells: Custom cable clamps, EMI/RFI shielding backshells, and angled versions.
- Harness Assembly: Complete cable harness assembly service, including molding, potting, and testing.
- Labeling & Marking: Laser marking of part numbers, logos, or pin maps on the shell.
Our proven OEM/ODM expertise, demonstrated in developing custom Latching Relays and Flash Relays, is fully applicable to creating a connector solution that integrates seamlessly into your design.
Production & Quality Assurance Process
Every YB3TAX/YB3TPA connector undergoes a rigorous, controlled manufacturing process:
- Precision Machining: Shells and complex metal parts are CNC machined to tight tolerances from certified material stock.
- Contact Fabrication & Plating: Contacts are stamped/formed and then plated with precise thicknesses of gold or silver in controlled plating lines.
- Injection Molding: Inserts, seals, and insulating components are molded from high-performance, qualified thermoplastics and elastomers.
- Sub-Assembly & Inspection: Contacts are assembled into inserts. Sub-assemblies undergo 100% visual and dimensional inspection.
- Final Assembly & Sealing Test: Complete connectors are assembled. Samples from each batch are subjected to rigorous environmental tests, including IP sealing tests (immersion) and dielectric tests.
- Electrical Testing & Traceability: Continuity and insulation resistance checks are performed. Full traceability of materials and processes is maintained.
This comprehensive quality regime, aligned with our processes for Solid State Relays and Polarized Relays, guarantees connectors that perform reliably in the field.
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