In the world of connectors, various technical terms are used, sometimes making it harder for a few people to understand things. The demand for military connectors is growing day by day due to their usability and durability among the applications used in difficult and extreme environmental conditions. The military connectors are available with derivative MIL-STD or MIL-SPEC connectors. A few of the most demanded military connectors are MIL DTL 5015, MIL-DTL-38999, MIL-DTL-24308, MIL-DTL-28748, and MIL-DTL-83513. Military connectors are critical components used in various military applications, including aircraft, ground vehicles, ships, and weapons systems.
These connectors are designed to provide a secure electrical connection in harsh environments, ensuring reliable operation in the field. MIL DTL 5015 is a set of general specifications that govern the design, performance, and testing of military connectors. It is important to understand these specifications to ensure that military connectors meet the requirements for their intended application.
In this article, we will understand the specification of these connectors in detail.
General Specifications of Military Connectors
MIL DTL 5015
This military standard, previously known as MIL-C-5015, is a circular connector that has front and rear release crimp contacts along with solder contacts. These connectors are best suitable for electronic and control circuits and are used in various applications including industrial, civil, defense, and many more. Every circular connector operates under a certain temperature range and for this one, the best suitable -55°C (-67°F) to either 125°C (257 °F), 175°C (347 °F), or 200°C (392 °F), completely depending upon the class of these connectors. The benefit of the DTL 5015 connector is it consists of multiple interlock systems which seal it perfectly and therefore best suitable for the applications used in extreme environmental situations.
This military standard, previously known as MIL-C-38999, is a series of connectors that are made with different types of coupling systems. The different coupling methods used in it are threaded, bayonet, and Breech. As we have already discussed that every connector operated at some particular temperature range, and the best suitable one for this is between -65 to +200°C. The other benefit of using this connector type is it uses removable crimp contacts which make them environmentally resistant. It is available in series I, II, III, and IV comprised of different coupling methods and various advantages.
This military standard, previously known as MIL-C-24308, are miniature connector that contains pins and sockets that operates in the temperature range of -55°C to 125°C. They are used in environmental conditions where weight and space are the major considerations. Due to their miniature structure, they are also known as D-Subminiature or D-Sub connectors. They are mostly used in missiles, aircraft, and other ground support systems. They are divided into various classes having various advantages and therefore they are used in different military applications depending on their various operating ranges.
These are specifically designed for designers that demand minimal space and weight usage without compromising the performance of the applications. The MIL-DTL-28748 connector also got popularity because of its high-quality material, high shock and vibration resistance, long life, and positive locking. This is the reason, these connectors are major used in applications used in aerospace, instrumentation, and other products like this.
This military standard, previously known as MIL-C-83513, is a rectangular connector with a polarized shell along with non-removable or solder crimp contacts. They are famous for their high dielectric strength, low contact resistance, high vibration and shock resistance, and high capability of carrying current, which makes them best suited for the application used in harsh conditions. Visit Allied Electronics Corporation.
MIL DTL 5015 Overview
MIL DTL 5015 is a set of general specifications that govern the design, performance, and testing of military connectors. It covers a wide range of topics, including contact arrangements, contact termination, insulation resistance, dielectric withstanding voltage, durability, salt spray resistance, temperature cycling, moisture resistance, insertion and extraction forces, mechanical shock and vibration, and more.
Construction and Materials
Military connectors are typically constructed using high-quality materials such as aluminum, stainless steel, and brass. These materials provide excellent resistance to corrosion, ensuring reliable performance in harsh environments. Military connectors are also designed to be robust and durable, with rugged construction that can withstand extreme temperatures, shock, vibration, and other environmental factors.
Contact arrangements refer to the number and arrangement of electrical contacts in a connector. MIL DTL 5015 specifies a wide range of contact arrangements, including circular and rectangular configurations. These contact arrangements can include anywhere from 2 to over 100 contacts, depending on the application.
Contact termination refers to the method used to connect the electrical contacts in a connector.DTL 5015 specifies several methods for contact termination, including solder, crimp, and screw termination. Each of these methods has its own advantages and disadvantages, and the appropriate termination method will depend on the specific application.
Insulation resistance refers to the ability of a connector to maintain electrical isolation between adjacent contacts. MIL DTL 5015 specifies minimum insulation resistance values for each contact arrangement, ensuring that connectors meet the requirements for their intended application.
Temperature cycling refers to the ability of a connector to withstand extreme temperature variations without damage or degradation. MIL DTL 5015 specifies minimum temperature cycling requirements for each contact arrangement, ensuring that connectors can maintain reliable performance in harsh environments.
Moisture resistance refers to the ability of a connector to resist moisture and prevent water from entering the electrical contacts. MIL DTL 5015 specifies minimum moisture resistance requirements for each contact arrangement, ensuring that connectors can maintain reliable performance in wet environments.
Insertion and Extraction Forces
Insertion and extraction forces refer to the amount of force required to insert or extract a contact from a connector. MIL DTL 5015 specifies maximum insertion and extraction force requirements for each contact arrangement, ensuring that connectors can be easily and reliably mated and unmated in the field.
Mechanical Shock and Vibration
Mechanical shock and vibration refer to the ability of a connector to withstand shock and vibration without damage or degradation. DTL 5015 specifies minimum mechanical shock and vibration requirements for each contact arrangement, ensuring that connectors can maintain reliable performance in high-stress environments.
MIL DTL 5015 is a set of general specifications that govern the design, performance, and testing of the military connector. By understanding these specifications, you can ensure that military connector meet the requirements for their intended application, providing reliable and secure electrical connections in harsh environments.
- What is MIL DTL 5015?
- What are military connectors used for?
- What materials are used to construct a military connector?
- How many contact arrangements are specified in MIL DTL 5015?
- What is the purpose of MIL DTL 5015’s salt spray resistance requirement?