Military Aviation Metal Sealed DC Relay GJRW-222MA TO-5 27V
Product Overview
The GJRW-222MA TO-5 27V is a precision-engineered Military Aviation Metal Sealed DC Relay designed for the most demanding aerospace and defense applications. This high-reliability component features a hermetically sealed TO-5 metal package that provides exceptional environmental protection while maintaining critical performance in extreme conditions. As part of our Military Metal Sealing Relay series, it delivers reliable switching for Aircraft Engine control systems, drone avionics, military communications, and other mission-critical circuits where component failure is unacceptable.
Product Features & Advantages
This relay represents the pinnacle of military-grade switching technology, offering distinct advantages over commercial alternatives such as standard PCB Board Relays or Automotive Relays:
- Advanced Hermetic Sealing Technology: Laser-welded metal can provides complete protection against moisture, dust, salt spray, and other contaminants, ensuring reliable operation from sea level to high-altitude environments.
- Military-Grade Durability: Engineered to withstand extreme vibration (up to 30G), mechanical shock, and wide temperature ranges from -65°C to +125°C, meeting rigorous military operational standards.
- High-Speed Switching Performance: Fast action time (≤4ms) and release time (≤4ms) ensure rapid circuit control for time-critical aerospace and defense applications.
- Dual-Function Contact Design: Capable of handling both standard power loads (1A at 28V DC) and sensitive low-level signal circuits (10-50µA at 10-50mV), providing exceptional versatility.
- Optimized Power Efficiency: Low coil power consumption (0.3-0.43W) reduces heat generation and minimizes power system burden in portable military and aerospace equipment.
- Compact TO-5 Package: Standard TO-5 footprint with weight under 3 grams offers space-saving design for modern avionics and military electronics where weight and space are critical constraints.
Built with the same precision engineering as our Polarized Relay JH-2S and Sealed magnetic Latching Relay series, the GJRW-222MA maintains consistency across YM's high-reliability product portfolio.
Technical Specifications
Complete performance parameters for engineering evaluation and system integration:
Electrical Specifications
- Rated Coil Voltage: 27V DC (standard military/aviation voltage)
- Contact Configuration: SPST-NO (Single Pole Single Throw Normally Open)
- Contact Rating:
- Standard Resistive Load: 1A at 28V DC
- Low-Level Signal Load: 10-50 µA at 10-50 mV
- Coil Power Consumption: 0.3W to 0.43W
- Initial Contact Resistance: ≤ 50 mΩ
- Contact Resistance After Life Test: ≤ 200 mΩ
- Insulation Resistance: > 500 MΩ (initial, normal atmospheric conditions)
Performance Characteristics
- Operational Life: Minimum 100,000 cycles at rated resistive load
- Action Time: ≤ 4 milliseconds
- Release Time: ≤ 4 milliseconds
- Incentive Pulse Width: 10 to 50 milliseconds
- Dielectric Strength:
- Normal Atmosphere: 500 Vr.m.s., 50Hz
- Low Pressure Conditions: 250 Vr.m.s., 50Hz
Physical & Environmental Specifications
- Package Type: TO-5 Metal Can
- Sealing Performance: Leakage Rate ≤ 1.0 × 10⁻³ Pa·cm³/s
- Weight: < 3 grams
- Operating Temperature Range: -65°C to +125°C (standard military grade)
Implementation & Installation Guide
For optimal performance in military and aerospace systems, follow these implementation steps:
- System Compatibility Check: Verify relay specifications match your application requirements, including voltage, current, and environmental conditions.
- PCB Layout Design: Design PCB with appropriate pad geometry for TO-5 package and maintain adequate clearance for high-voltage applications.
- Coil Drive Circuit Protection: Implement proper flyback protection (diode or TVS) to suppress voltage spikes from the inductive coil.
- Thermal Management Planning: Ensure adequate airflow or heat sinking when operating near maximum rated current in elevated ambient temperatures.
- Handling Precautions: Use ESD protection during handling and assembly to prevent damage to sensitive internal components.
- Final System Testing: Test relay operation under simulated operating conditions before final system deployment.
Application Scenarios
The GJRW-222MA is specifically engineered for applications where reliability directly impacts mission success and operational safety:
- Aerospace Flight Control Systems: Aircraft and helicopter flight control interfaces, navigation system switching, and cockpit instrumentation.
- Military Drone (UAV/UAS) Systems: Power distribution modules, payload activation (sensors, cameras, countermeasures), and communication system controls.
- Defense Communication Equipment: Encrypted communication systems, radar interfaces, and electronic warfare equipment.
- Ground Military Vehicles: Armored vehicle electronic systems, missile launch controls, and mobile command post equipment.
- High-Reliability Industrial: While distinct from our Industrial Power Relay series, the GJRW-222MA may be specified for extreme environment industrial applications including oil & gas, mining, and remote monitoring systems.
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Value Proposition
The GJRW-222MA delivers significant value to military and aerospace procurement teams:
- Enhanced System Reliability: Reduces system failures and maintenance requirements through proven military-grade construction.
- Reduced Lifecycle Costs: Extended operational life and reduced failure rates lower total cost of ownership over system lifecycle.
- Improved Mission Readiness: Consistent performance in extreme conditions ensures equipment availability when needed most.
- Simplified Qualification Process: Pre-qualified to military standards reduces time and cost for system certification.
- Weight & Space Optimization: Compact TO-5 package enables more efficient system design in space-constrained applications.
Certifications & Compliance
The GJRW-222MA is designed and manufactured to meet rigorous international military and aerospace standards:
- Performance compliant with relevant sections of MIL-PRF-6106 for established reliability electromagnetic relays
- Environmental testing per MIL-STD-810 methods for vibration, shock, and temperature extremes
- Materials and processes compliant with RoHS and REACH environmental directives
- Manufactured under quality management systems suitable for aerospace and defense applications
Customization Options
YM offers comprehensive customization capabilities for the GJRW-222MA platform to meet specific program requirements:
- Voltage Variants: Custom coil voltages tailored to specific system requirements
- Special Pin Configurations: Modified lead materials, plating, or forming for specific interface requirements
- Enhanced Testing & Screening: Additional screening including burn-in, thermal cycling, or accelerated life testing
- Special Marking & Traceability: Custom part numbering, date coding, and enhanced traceability documentation
- Environmental Performance Enhancements: Special sealing or material treatments for specific environmental challenges
Production Process & Quality Assurance
Every GJRW-222MA relay undergoes a rigorous, controlled manufacturing process:
- Material Qualification: All materials sourced from qualified suppliers with full traceability and military-grade certification
- Precision Component Manufacturing: Critical components manufactured to tight tolerances using automated processes
- Controlled Environment Assembly: Assembly conducted in cleanroom conditions to prevent contamination
- Laser Hermetic Sealing: Automated laser welding in inert atmosphere achieves specified leak rates
- Comprehensive Testing: 100% electrical testing plus environmental and life testing on sample lots
- Final Quality Verification: Visual inspection, final electrical verification, and proper ESD-safe packaging
Frequently Asked Questions (FAQ)
Q1: What is the difference between TO-5 and other relay packages for military applications?
A: The TO-5 package offers superior hermetic sealing capability compared to plastic packages, providing better environmental protection. It also has excellent thermal characteristics and is a standard footprint in military and aerospace electronics, making it compatible with existing designs.
Q2: Can the GJRW-222MA be used in space applications?
A: While the relay has excellent high-altitude performance, space applications require additional screening for outgassing and radiation tolerance. We offer space-qualified variants with enhanced testing—please consult with our technical team for specific space qualification requirements.
Q3: How does this relay compare to Solid State Relay technology for military use?
A: The GJRW-222MA offers advantages in high-current applications with lower conduction losses, true galvanic isolation, and inherent resistance to electromagnetic interference. Solid State Relays excel in high-speed switching and long life for frequent cycling applications. The optimal choice depends on specific application requirements.
Q4: What is the typical delivery time for military-grade quantities?
A: Standard military-grade production typically requires 12-18 weeks for initial orders, depending on quantity and specific testing requirements. Custom configurations may require additional qualification time.
Q5: Do you provide reliability data and failure analysis support?
A: Yes, we provide comprehensive reliability data including MTBF calculations per military standards and support failure analysis for qualified military and aerospace customers.
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