What is an aviation plug?
Aviation plugs originated in the 1930s in the manufacture of military aircraft. Today, applications for aviation plugs include not only military equipment and manufacturing, but also reliable operating environments such as medical equipment, automation, and rail transportation. General aviation plugs include contacts that transmit data and power.
What are the basic characteristics and classifications?
Typically, aviation plugs are surrounded by a plastic or metal shell that is embedded in an insulating material to maintain alignment. Since they are usually paired with cables, these terminals are particularly resistant to external interference and accidental decoupling.M12, M8, M5, M16, 5/8', and M23, 7/8' aviation plugs are the majority of aviation plugs used for non-standard automation.
Classification of aviation plugs
1. Classification of aviation plugs according to the number of pins (pins, cores)
Usually, there are three, six, or eight pins (number of pins, number of cores) on each end of the aviation plug.
2. Distinguish according to manufacturing specifications, size, connection angle, and connection disconnection method.
The standard of air plug: standard air plug usually refers to its design in line with the German national standards or the United States military standards (U.S. military standards). According to size can be divided into miniature, small air plugs.
2.1 German standard air plug
DIN standard (German national standardization agency): The DIN air plug is in line with German electrical standards, with high-frequency function and icon function, protection of the metal shell, and round terminals with concave surfaces. This structure ensures that they are correctly paired.
2.2 U.S. military standard air plugs
Military specification (MIL-standard): MIL-standard connectors are designed according to the best practices for military and aerospace applications. These rugged connectors are ideal for high-impact use and are easily resistant to extreme environments. Due to the epoxy sealing around the terminals, some MIL connectors are virtually hermetically sealed or airtight, and most are watertight.
Micro or Nano: Micro and nanocarriers have smaller pin and jack diameters and narrower spacing between them, which helps to minimize surface space on the terminal face and reduces the extra weight of the connector on the component.
Aviation plug terminal connection methods and advantages
1.1 Terminal connection method
Like most types of electrical connectors, aviation plugs have multiple terminal connections. The nature of the connection between the electrical contacts in each connector element depends on the type of terminal selected. The choice of these types of terminals depends primarily on cost, ease of connection and disconnection, and protection against error, wear, and environmental damage.
Circular aviation plugs are used for insulation displacement, soldering, winding, screw or lug connections, and pressure connections. Circular aviation plugs are available in a wide range of contact sizes and shell sizes, from M8/M5/M12 to M12/M16, depending on the specific purpose of the connection. Smaller shell diameters are used for sensors and other precision and high-sensitivity applications, while larger shell diameters are used for transmitting power, e.g. in agricultural machinery.
1.2 Advantages of aviation plugs
Ideal for applications requiring electrical connectors with more robust terminals. Their cylindrical shape makes them particularly resistant to mechanical turbulence and shock.
1. Waterproof, moisture-proof, rain-proof, sun-proof, corrosion-proof.
2. Flame-retardant, oxidation-resistant, and environmentally friendly (all products are from green production lines).
3. Improved production process: simplified assembly process and mass production process.
4. Easy maintenance: No need to cut cables, electrical plastic sleeves, etc. In case of malfunction, just rotate the ends of the waterproof connector, which is convenient for the maintenance of waterproof products such as LED, solar energy, and geothermal.
5. Improve design flexibility: the use of connectors allows engineers to design and integrate new products and have greater flexibility when using meta-components to form systems
Aviation plugs are widely used in the following fields
Aerospace: Due to their reliability and durability, aviation plugs can work in high altitude, high speed, and high and low-temperature environments and maintain good electrical and mechanical properties. In addition, due to its waterproof, dustproof, and corrosion-resistant characteristics, aviation plugs can be used in a variety of harsh environments.
Military field: Aviation plugs are an important part of the military field. They are widely used in tanks, warships, airplanes, and other military equipment between the electronic equipment. Due to its reliability and durability, circular connectors can work in a war environment and maintain good electrical and mechanical properties to ensure the reliability of information transmission and the effectiveness of equipment. In addition, circular connectors are waterproof, dustproof, corrosion-resistant, and other characteristics to adapt to a variety of harsh war environments.
Industrial field: aviation plugs play an important role in many important fields, these application scenarios require aviation plugs with high reliability, durability, and adaptability. For example, they can be used in factory automation equipment to connect sensors and control systems to ensure accurate data transmission. Avionic plugs are also used in the petroleum, chemical, and heavy industries.
Replacement intervals for aviation plugs
In general, plug replacement intervals should be evaluated on the basis of actual usage, and the following are some suggested considerations:
Regularly check the performance of aviation plugs, including indicators such as transmission speed, contact resistance, and insulation resistance.
When degraded or non-compliant performance is detected, immediate consideration should be given to replacing the plug.
Regularly record the usage time and the number of plugs and pulls of the plugs to assess the degree of wear.
When the use time or the number of plugs reaches the expected value, the replacement of the plug should be considered.
The service life of aviation plugs is affected by a number of factors, including the following:
In harsh flight environments, aviation plugs may be subjected to temperature, humidity, vibration, and other factors that can degrade their performance. Particularly in extreme temperatures or humidity, the plug material may expand or contract, reducing the accuracy of the pin-to-socket fit.
Frequent plugging and unplugging of the receptacle may wear down the receptacle pins and sockets, reducing the contact performance of the connector. Over time, the metal inside the receptacle also wears away, affecting its service life. Therefore, regular maintenance and care will help extend the life of the aviation plug. Without regular maintenance and care, the plug may become worse due to dust accumulation, oxidization, and other reasons.
When replacing aviation plugs, the following points need to be noted:
When performing a replacement of an aviation plug, make sure that the new plug matches or is compatible with the prototype model to ensure that the new plug will meet the requirements of the system.
Prior to replacement, ensure that the equipment is completely de-energized to prevent electrical accidents.
When installing the new plug, follow the manufacturer's instructions to ensure that the socket and plug are aligned and secured with appropriate tools.
Upon completion of the installation, perform the necessary performance tests to determine if the new plug is functioning properly.
Post time: Jul-31-2024