GJRW Series Military Relays Complete Guide - GJRW Series Relays

GJRW Series Military Relays Complete Guide: The Comprehensive Switching Solution

In the demanding world of military and aerospace electronics, standardization and reliability are paramount. The GJRW Series Military Relays represent a comprehensive family of hermetically sealed, high-reliability switching components designed to meet the most stringent requirements. This complete guide provides procurement managers, system designers, and maintenance professionals with an in-depth understanding of the series' capabilities, variants, and optimal applications across Military Aviation systems, satellite communications, Aircraft Engine controls, and rugged industrial environments.

Understanding the GJRW Series Designation System

The GJRW naming convention follows a logical structure that reveals key characteristics at a glance:

Typical GJRW Part Number Structure: GJRW - XXX - YY - ZZ

• GJRW: Base series identifier for hermetically sealed, military-grade relays.
• XXX: Numerical code indicating contact configuration and current rating (e.g., 102 for DPDT 2A, 503 for 4PDT 5A).
• YY: Coil voltage specification (e.g., 12 for 12VDC, 27 for 27VDC, 05 for 5VDC).
• ZZ: Suffix indicating special features, termination style, or revision (e.g., M for military version, S for solder terminals, P for plug-in).

Example: GJRW-102-27M indicates a DPDT, 2A contact rating, 27VDC coil, military-specified relay.

Series Overview: Key Models and Their Specifications

The GJRW series encompasses a range of models to address different switching needs.

Primary Model Categories and Applications

Core Technical Features and Benefits

1. Hermetically Sealed Metal Construction

All GJRW series relays feature welded metal enclosures providing:

• Protection against moisture, dust, and corrosive atmospheres
• Stable internal atmosphere for consistent contact performance
• Superior heat dissipation compared to plastic housings
• Inherent EMI/RFI shielding

2. Military-Grade Reliability

1. Extended Temperature Range: Operation from -65°C to +125°C (certain models to +150°C)
2. High Vibration/Shock Resistance: Typically 10-2000Hz at 20g vibration; 50-100g shock resistance
3. Long Operational Life: Mechanical life >1,000,000 operations; Electrical life: 100,000+ operations at rated load
4. Low Contact Resistance: Typically <100mΩ, ensuring minimal voltage drop

3. Versatile Termination Options

• PCB Mount: Standard through-hole pins for direct board mounting
• Plug-in Sockets: For easy field replacement and maintenance
• Quick-Connect Terminals: For industrial panel wiring
• Solder Cup Terminals: For high-reliability aerospace wiring harnesses

Industry Trend: Miniaturization with Maintained Performance

The ongoing trend in military and aerospace electronics is toward higher density packaging without compromising reliability. Recent advancements in the GJRW series include:

• Development of compact "half-size" versions maintaining full specifications
• Integration of internal suppression diodes in select models
• Improved contact materials allowing higher current in same package size
• Compatibility with automated assembly and inspection processes critical for OEM/ODM Manufacturers

5 Critical Selection Factors for Russian & CIS Market

1. Temperature Performance Validation: Demand certified test data showing performance at temperature extremes, particularly -65°C operability, crucial for Arctic and Siberian operations.
2. GOST Standard Compliance Documentation: Require explicit documentation showing compliance with relevant GOST standards (e.g., GOST 16121-86) beyond just MIL specifications.
3. Localized Technical Documentation: Availability of specifications, installation guides, and maintenance manuals in Russian language.
4. Long-Term Supply Chain Stability: Manufacturer commitment to long-term production and support for legacy systems common in regional defense and industrial platforms.
5. Customization Capability: Ability to provide minor modifications (special pin lengths, marking requirements) to meet specific platform integration needs.

YM's GJRW Series Manufacturing Excellence

Producing the complete GJRW series requires sophisticated manufacturing capabilities. Within our 350,000 sq.m. advanced manufacturing campus, we operate dedicated cleanroom facilities for relay assembly. Each GJRW relay undergoes:

• Automated coil winding with precision tension control
• Computer-controlled contact welding ensuring consistent quality
• 100% electrical testing including contact resistance, insulation resistance, and operate/release time verification
• Hermeticity testing per MIL-STD-883 Method 1014
• Environmental stress screening for high-reliability models

R&D Innovations in Contact Technology

Our R&D team has developed proprietary contact materials specifically for the GJRW series. The "GJRW-Gold" contact system uses a unique gold alloy matrix that provides:

• Exceptionally low and stable contact resistance (<50mΩ)
• Superior resistance to organic contamination
• Extended life in low-current (dry circuit) switching applications
• Excellent performance in high-vibration environments

Application Guidelines and Best Practices

Selection Process Flowchart

1. Define Load Requirements:
   • Voltage and current (inrush and steady-state)
   • Load type (resistive, inductive, capacitive)
   • Switching frequency
2. Determine Environmental Conditions:
   • Operating temperature range
   • Vibration and shock levels
   • Exposure to contaminants
3. Select Contact Configuration:
   • Number of poles needed
   • Need for normally closed contacts
   • Isolation requirements between poles
4. Choose Coil Voltage:
   • Match to available control voltage
   • Consider power consumption constraints
5. Specify Termination Style:
   • Based on assembly method and maintenance requirements

Installation Recommendations

Standards and Certifications

The GJRW series is designed to meet multiple international standards:

• MIL-PRF-6106: U.S. military performance specification for relays
• GOST 16121-86: Russian standard for sealed electromagnetic relays
• IEC 61810-1: International standard for electromechanical elementary relays
• RTCA DO-160: Environmental conditions for airborne equipment
• AS9100: Quality management system for aerospace

Maintenance and Troubleshooting

Preventive Maintenance Schedule

Common Issues and Solutions

• Failure to Operate: Check coil voltage, continuity; verify driver circuit
• Intermittent Operation: Inspect for loose connections; measure contact resistance
• Overheating: Verify load current; check for proper ventilation
• Excessive Bounce: May indicate mechanical wear; consider replacement

Frequently Asked Questions (FAQ)

Q1: What is the difference between standard GJRW and GJRW-M versions?

A: The GJRW-M suffix indicates military-specified versions that undergo additional screening and testing per military standards. This typically includes:

• Extended temperature range testing
• Additional vibration and shock testing
• Lot traceability and documentation requirements
• Extended burn-in periods

Standard GJRW versions meet commercial aerospace and industrial requirements while M versions meet specific military contract requirements.

Q2: Can GJRW relays be used in space applications?

A: Standard GJRW relays are designed for airborne and ground applications. For space applications, we offer GJRW-S versions that include:

• PIND testing to eliminate loose particles
• Enhanced hermeticity testing
• Radiation tolerance characterization
• Outgassing testing per NASA standards

These versions are specifically qualified for satellite and spacecraft applications.

Q3: What is the lead time for custom GJRW configurations?

A: Lead times vary based on customization level:

• Standard configurations: 8-12 weeks
• Minor modifications: 12-16 weeks
• Fully custom designs: 20-30 weeks including qualification testing

We recommend contacting our applications engineering team early in the design process for custom requirements.

Q4: How does the latching version conserve power in battery systems?

A: GJRW-L series latching relays use a permanent magnet or mechanical latch to maintain their state. They only consume power during the brief switching pulse (typically <10ms), then maintain position with zero power. This can reduce system power consumption by 90-99% compared to standard relays in applications where states are maintained for long periods, such as in remote monitoring systems or battery-backed Train control circuits.

Reference Sources

• U.S. Department of Defense. (2018). MIL-PRF-6106U: Performance Specification for Relay, Electromagnetic, Established Reliability.
• International Electrotechnical Commission. (2020). IEC 61810-1: Electromechanical elementary relays - Part 1: General and safety requirements.
• SAE International. (2019). ARP9012: Guidelines for the Specification of High Reliability Electromechanical Relays for Aerospace Applications.
• NASA Electronic Parts and Packaging Program. (2021). Relay Selection Guide for Space Applications.
• Defense Electronics Forum. (2024). "Trends in Military Relay Technology and Supply Chain Management." Military Electronics Journal, 42(3), 45-52.
• Wikipedia contributors. (2024). "Relay" and "Hermetic seal." Wikipedia, The Free Encyclopedia. Retrieved from relevant pages.