Aviation Inches Switch WK1-1

Product Overview

The WK1-1 is a high-precision Military Inches Switch specifically engineered for space-constrained critical applications in drone systems, aircraft engines, train controls, and Aviation Electronics. As one of the most compact switches in its class, it delivers exceptional reliability and performance while minimizing weight and footprint. Designed to meet rigorous military and aerospace standards, the WK1-1 represents YM's expertise in miniature component manufacturing, complementing our broader portfolio of Military Metal Relay and Aviation Connector solutions for demanding environments.

Technical Specifications

• Model Number: WK1-1
• Switch Type: Miniature electromechanical inches switch
• Coil Power Consumption: (0.3 - 0.43) Watts
• Contact Load & Electrical Life: Resistive load, 1A at 28V DC, minimum 100,000 operations
• Low-Level Signal Capability: Handles (10-50) μA at (10-50) mV for 100,000 operations
• Contact Resistance: Initial ≤50mΩ; Post-life test ≤200mΩ
• Switching Speed: Action time ≤4ms; Release time ≤4ms; Incentive pulse width (10-50) ms
• Dielectric Strength: 500V RMS @ 50Hz (normal pressure); 250V RMS @ 50Hz (low pressure conditions)
• Insulation Resistance: >500 MΩ (standard conditions); >50 MΩ after high-level life testing
• Weight: Under 3 grams (one of the lightest switches in its category)
• Environmental Sealing: Maximum leakage rate ≤ 1.0 x 10⁻³ Pa·cm³/s
• Operating Temperature Range: Performance validated at reference condition (25°C) and compatible with systems using Aviation Temperature Sensors
• Mounting Style: Designed for PCB mounting or miniature panel installation

Product Features & Competitive Advantages

1. Ultra-Compact Form Factor: Exceptionally small dimensions make it ideal for space-critical applications where every millimeter counts, complementing miniature PCB Signal Relay designs.
2. Military-Grade Environmental Protection: Advanced hermetic sealing (≤10⁻³ Pa·cm³/s) provides superior defense against moisture, dust, and corrosive elements—comparable to sealing standards of Aviation Oil Sealed Valves.
3. High-Speed, Low-Power Operation: Combines fast ≤4ms switching with minimal (0.3-0.43W) coil consumption, ideal for energy-sensitive systems like those using New Energy Relay technologies.
4. Exceptional Durability in Miniature Package: Despite its small size, rated for 100,000+ operations under rated load, matching the reliability expectations of larger Industrial Power Relay components.
5. Precision Contact Design: Micro-machined contacts ensure stable electrical performance and low contact resistance throughout operational life.
6. Vibration and Shock Resistant: Engineered to withstand extreme mechanical stresses common in aerospace and military applications, similar to robustness required for Military Electronic Horn systems.
7. Lightweight Construction: At less than 3 grams, it provides maximum functionality with minimal mass impact—critical for weight-sensitive UAV and aerospace designs.

Installation and Integration Guidelines

1. Circuit Design Verification: Confirm electrical requirements match switch specifications (28VDC, 1A resistive) and that the miniature size fits your layout constraints.
2. Precision Mounting: For PCB mounting, ensure proper pad layout and use recommended soldering profile. For panel mounting, use appropriate miniature hardware.
3. Careful Handling: Use appropriate tools for installation—avoid excessive mechanical stress on the miniature housing during handling.
4. Sealing Verification: If used in sealed assemblies, ensure the switch's integral seal interfaces properly with surrounding gaskets or potting compounds.
5. Functional Testing: Perform in-circuit testing of switching operation, timing, and insulation resistance before full system integration with components like Hydraulic Circuit Breakers or Aviation Pressure Sensors.

Application Scenarios

The WK1-1 Inches Switch is engineered for applications where space and weight are critical constraints:

• Miniature UAV Flight Control Systems: Limited-space circuit boards for micro-drones, where switch size directly impacts payload capacity.
• Aircraft Engine Monitoring Units: Compact sensor interface circuits within engine control units where space is severely limited.
• Wearable Military Electronics: Miniature control circuits in soldier-worn equipment, helmet systems, and portable communication devices.
• Aviation Instrumentation Panels: High-density instrument clusters where multiple switches must fit in constrained panel space.
• Rail Transportation Control Modules: Compact control units in modern train systems where miniaturization is essential.
• Medical Aviation Equipment: Miniature controls in airborne medical systems and portable monitoring equipment.
• Satellite and Spacecraft Subsystems: Where weight and space optimization are paramount considerations.
• Industrial Automation Miniaturization: Compact machinery controls where space constraints prohibit standard-sized switches.

Value Proposition for Design Engineers & Procurement

• Enable Miniaturization: Allows design of smaller, lighter systems without compromising reliability—critical for next-generation aerospace and defense platforms.
• Weight Reduction: At under 3 grams, contributes directly to overall system weight reduction, particularly valuable in UAV and aircraft applications.
• Increased Circuit Density: Enables higher component density on PCBs and in assemblies, supporting trend toward more compact system designs.
• Reliability in Miniature Form: Delivers military-grade reliability in a miniature package, reducing the traditional trade-off between size and durability.
• Simplified Inventory Management: Single miniature switch solution that can replace larger components in redesigned systems.
• Design Flexibility: Provides switching solution for applications where previously no suitable miniature component was available.

Certifications & Compliance

The WK1-1 Inches Switch is designed and manufactured to meet or exceed performance requirements of international standards relevant to miniature components for aviation (including considerations for DO-160 environmental testing), military applications (with design parameters suitable for miniaturized military equipment), and transportation systems. Our manufacturing processes comply with stringent quality management systems appropriate for miniature component production, and we provide comprehensive technical documentation to support customer qualification and certification efforts.

Customization & OEM/ODM Services

YM offers specialized customization options for the WK1-1 miniature switch series:

• Custom actuation forces and travel distances for specific application requirements
• Specialized terminal configurations (straight, right-angle, surface mount variations)
• Custom sealing specifications for unique environmental challenges
• Modified electrical parameters for specific circuit requirements
• Special marking and identification for miniature component traceability
• Application-specific testing and validation for miniature component reliability
• Bulk packaging options optimized for automated assembly processes

Our expertise in OEM and ODM services for precision components, demonstrated across our Automotive Relay and PCB Board Relay product lines, ensures we can tailor miniature switch solutions to your exact specifications.

Production Process & Quality Assurance for Miniature Components

1. Micro-Precision Manufacturing: Advanced micro-machining and stamping processes create components with tolerances suitable for miniature applications.
2. Clean Room Assembly: Critical assembly steps performed in controlled environments to prevent contamination of miniature components.
3. Micro-Scale Plating: Precision electroplating processes apply consistent contact surfaces at microscopic scale.
4. Automated Micro-Assembly: Robotic assembly systems handle and assemble miniature components with precision beyond human capability.
5. 100% Electrical Testing: Every switch undergoes comprehensive testing including contact resistance, operate/release time, insulation resistance, and dielectric strength using micro-probe systems.
6. Sealing Verification at Micro Scale: Specialized testing validates hermetic seal integrity for miniature components.
7. Magnified Visual Inspection: High-magnification inspection ensures quality of miniature features and assemblies.
8. Final Quality Audit & Micro-Traceability: Comprehensive inspection and permanent micro-marking ensure full traceability for miniature components.

Compatible Systems & Design Considerations

The WK1-1 Inches Switch is designed for integration into modern miniaturized systems. When designing with this component, consider: thermal management in high-density layouts, appropriate soldering techniques for miniature terminals, and mechanical protection in high-vibration environments. For complete miniature system solutions, consider pairing with YM's complementary products such as Aviation Microswitches, miniature Solid State Relays, and compact Aviation Copper Fuse Holders to create reliable, space-optimized control systems.