KN1A-202DM 250V 5A Military Aviation Switch -
High-Current Reliability for Demanding Aerospace Applications
YM's KN1A-202DM Military Aviation Switch sets a new standard for high-current switching in critical aerospace, defense, and industrial environments. Rated for 250V and 5A operation, this robust switch delivers exceptional power handling capabilities while maintaining the precision and reliability required for drone systems, aircraft engine controls, train subsystems, and aviation power distribution. Engineered with technologies proven in our Military Metal Relay and Industrial Power Relay product lines, the KN1A-202DM combines high-current capacity with military-grade durability.
As a cornerstone of YM's aviation component portfolio, this switch integrates seamlessly with our comprehensive range of Military Aviation Connectors, Aviation Rocker Switches, and power management systems, providing engineers with a dependable solution for demanding electrical applications.
Technical Specifications
Electrical Performance Parameters
- Voltage Rating: 250V operational capability for both AC and DC applications.
- Current Rating: 5A continuous current capacity, suitable for power distribution and high-load switching.
- Coil Power Consumption: Energy-efficient operation between 0.3W and 0.43W.
- Contact Load & Lifetime:
- High-Current Switching: Rated for 5A at 250V, with verified operational life exceeding 1,000,000 cycles under rated conditions.
- Low-Level Signal Capability: Maintains reliability for (10-50)μA at (10-50)mV signals, enabling dual-use in control and monitoring circuits.
- Contact Resistance: Excellent conductivity with initial contact resistance ≤50mΩ. After full lifecycle testing, resistance remains ≤200mΩ, ensuring minimal voltage drop and power loss.
- Switching Speed: Fast response with actuation time ≤4ms and release time ≤4ms, even under high-current conditions.
- Dielectric Strength:
- Standard Conditions: Withstands 500V RMS at 50Hz.
- Low-Pressure Conditions: Rated for 250V RMS at 50Hz, ensuring safety at high altitudes.
- Insulation Resistance: Superior isolation with >500MΩ initially and >50MΩ after accelerated life testing.
Physical & Environmental Specifications
- Weight: Engineered for high-current applications while maintaining lightweight construction under 3 grams.
- Hermetic Sealing: Advanced sealing with maximum leakage rate ≤10⁻³ Pa·cm³/s. This Aviation Oil Sealed Valve-grade protection ensures reliability in contaminated environments.
- Control Compatibility: Compatible with incentive pulse widths from 10ms to 50ms for flexible integration with various controllers.
- Temperature Performance: Specifications characterized at 25°C with validated operation across extended military temperature ranges.
Product Features & Competitive Advantages
- High-Current Capacity: 250V/5A rating enables direct switching of substantial loads, reducing the need for additional relay stages in power distribution systems.
- Military-Grade Construction: Incorporates ruggedized design principles from our Military Electronic Horn and Military Pressure Sensor manufacturing, ensuring resilience in extreme conditions.
- Advanced Thermal Management: Optimized contact design and materials dissipate heat effectively during high-current operation, enhancing reliability and lifespan.
- True Hermetic Sealing: Utilizes proprietary metal-to-ceramic sealing technology from our Metal Sealing Relay series, guaranteeing long-term integrity in harsh aerospace environments.
- Dual-Function Capability: Engineered to handle both high-power switching and sensitive low-level signals with equal reliability, offering design flexibility.
- Enhanced Arc Suppression: Special contact geometry and materials minimize arcing during high-current switching, extending contact life and reducing electromagnetic interference.
- Optimized Integration: Designed for straightforward mounting and connection, compatible with PCB Board Relay layouts and high-current wiring for Aviation Magnetic Valves and actuators.
Installation & Integration Procedure
- Application Assessment: Verify the switch's 250V/5A rating matches your circuit requirements, including inrush current considerations for inductive loads.
- Thermal Management Planning: Ensure adequate heat dissipation in the mounting location, especially for continuous high-current applications.
- Secure High-Current Mounting: Mount the switch firmly using appropriate hardware. For high-vibration environments, consider additional vibration damping.
- Proper High-Current Wiring: Use appropriately sized wires and high-quality terminals rated for 5A continuous current. Ensure secure connections to minimize resistance and heating.
- Sealing System Verification: Confirm the integrity of environmental seals around the switch installation to maintain overall protection.
- Pre-Operational Testing: Conduct thorough testing including high-current switching verification, contact resistance measurement, and thermal performance under load.
- System Integration & Validation: Install into the final system and execute comprehensive system-level tests including load cycling, thermal cycling, and environmental validation.
Application Scenarios & Business Value
Primary Application Areas
- Drone & UAV Power Systems: High-current switching for motor controllers, payload power distribution, and charging systems in commercial and military drones.
- Aircraft Power Distribution: Switching for avionics power buses, lighting systems, auxiliary power units, and engine control circuits in both commercial and military aircraft.
- Rail Transportation Power Management: Control of traction systems, cabin power distribution, and auxiliary equipment in modern trains and rail systems.
- Military Vehicle Systems: Power switching in armored vehicles, communication shelters, and portable power systems requiring robust high-current capability.
- Industrial Power Control: Suitable for machinery power control, test equipment power switching, and industrial automation systems requiring reliable high-current switching.
Value Proposition for Engineering & Procurement
- Reduces System Complexity: 250V/5A capability eliminates need for additional power relays in many applications, simplifying designs and reducing component count.
- Lowers Total Cost of Ownership: High reliability and long lifespan reduce maintenance costs and downtime, while simplified designs lower assembly and inventory costs.
- Enhances System Safety: Military-grade construction and reliable high-current switching improve overall system safety and reduce failure risks in critical applications.
- Improves Power Efficiency: Low contact resistance minimizes power loss and heat generation, improving overall system efficiency.
- Simplifies Supply Chain: Sourcing from YM, an established manufacturer with expertise in Automotive Relay and New Energy Relay systems, ensures consistent quality and technical support.
- Accelerates Development Cycles: Proven performance and reliability reduce testing and validation time, speeding time-to-market for new products.
Manufacturing Process & Quality Assurance
The KN1A-202DM undergoes a rigorous, multi-stage manufacturing process designed specifically for high-current reliability.
- Precision High-Current Component Fabrication: Contacts and terminals are manufactured from premium materials using precision stamping and forming processes optimized for high-current carrying capacity.
- Specialized Thermal Management Features: Components are designed and processed to optimize heat dissipation during high-current operation.
- Controlled Sealing Process: Hermetic sealing is applied in a controlled environment using technology refined through production of Aviation Oil Sealed Valves.
- Automated High-Current Testing: Every unit undergoes automated testing at rated current (5A) and voltage (250V), including contact resistance, insulation resistance, dielectric strength, and switching performance under load.
- Extended Lifecycle Validation: Statistical samples undergo accelerated lifecycle testing at full rated current to validate contact durability and thermal performance.
- Comprehensive Final Inspection: Each switch receives final visual, dimensional, and functional inspection before packaging in protective materials with clear electrical rating identification.
Compliance & Customization Services
Standards Compliance
The KN1A-202DM is designed and manufactured to meet or exceed performance requirements of relevant military (MIL-SPEC), aerospace (RTCA/DO-160), and industrial standards for high-current switching components. Our quality management system ensures full traceability and process control.
Customization Options
YM offers comprehensive customization for the KN1A-202DM, leveraging our experience with custom PCB Signal Relay and specialized switching solutions:
- Current Rating Variations: Custom configurations for specific current requirements above or below standard 5A rating.
- Voltage Specification Adjustments: Modifications for specific voltage requirements or special insulation needs.
- Terminal Configuration: Custom terminal types, sizes, or arrangements for specific mounting or connection requirements.
- Thermal Enhancement Options: Special heat sinking features or materials for extreme high-current or high-temperature applications.
- Actuator Customization: Options for different actuator styles, forces, or indications for specific human-machine interface needs.
- Application-Specific Validation: Capability to perform custom testing protocols including specific environmental, current cycling, or performance tests as required.
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