Transcript AVIM Connector

DIAMOND
AVIM Connector
Fiber optic connector for aero-space applications
© DIAMOND SA / 03-01 / 1
AVIM Connector

The AVIM connector family, is designed to be used in high
reliability space and aerospace programs.
These connectors are designed as Single Terminus, Fiber
Optic Connectors applicable for Single mode and Multimode
Fibers.
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Product Features
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Single mode / Multimode / PM Fiber Compatible
Active aligned core for lowest insertion loss
Unique AVIM 2-piece cleanable Adapter for black box applications
Environmentally robust, survives vibration, shock, thermal cycling
and repeated mating.
Wide temperature operating range: -55°C to +125°C
Low out gassing materials applied conform to space applications
Sealed, flange mounted bulkhead allows pressure feed through
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History

In spring of 95, LMC was looking for a SM connector with the
following characteristics:
Singlemode 980nm Fiber with 6.3µm Core
IL less than <0.5dB
RL better than 55dB
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February through May 95 Dennis Horwitz at RIFOCS Corp.
evaluated with the Customer (LMC) the feasibility of using the
Diamond AVIO Connector.
In May 95 LMC made the decision to adopt the Diamond
connector technology because it offers superior precision namely
the second crimping technology.
June 95 LMC visited Diamond SA and submitted detailed
specifications. Diamond developed the new “AVIM” connector and
first prototypes were available by the end of 95.
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Project Milestones
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End of 1995 Diamond delivered first samples of Bulkhead and
Connectors
RIFOCS developed the termination process meeting MIL-I-45208
Quality System together with LMC.
1996 Initial tests revealed problems!
Key Nut did not hold up during 500 mating cycles. A new stainless steel key nut was produced
and successfully tested.
Cable retention needed to be improved using more precise crimp sleeves.
Epoxy curing cycle needed to be improved for meeting temperature performance.
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Project Milestones
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Big problem : Vibration Test at 46.6Grms failed!
We found certain resonance frequencies caused unacceptable high acceleration. The two connector
end faces moved against each other and caused surface damage (fretting). The reason was the
floating sleeve went into uncontrolled resonance and amplified the acceleration forces. See picture.
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Solution to meet the 46.6Grms we had to keep the split sleeve in
the ferrule axis under a certain tension. This solution has a
damping effect and eliminates the resonance.
Success - Finally! LMC tested the new adapter at 46.4Grms in all
three axis and over double the required vibration time.
June 1997: The AVIM connector passed all tests as specified with
success.
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Specifications
Fiber
- Single Mode 980nm
Optical Requirements
- IL max. 0.5dB
- RL PC >45dB
- APC >55dB
Thermal Cycling
- Temperature range -55°C (+0, -5°C) to +125°C
(+5, -0°C)
Ferrules - Active Alignment
- The active alignment ferrule and inner sleeve shall be
machined copper alloy. The outer sleeve shall be
machined tungsten carbide.
Dissimilar Materials
- Potential between the anode and cathode. (Standard
Electrode Potential, V.) All parts are positive (+0.15
until +0.25). Only the ferrule sleeve (tungsten
carbide) is negative (-0.2). The combination between
those will be ok, based on information from LMC.
Out gassing
- All non-metallic materials shall not emit greater than
1.0% Total Mass Loss (TML) and greater than 0.1%
Collected Volatile Condensable Materials (CVCM).
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Shock
- The adapter shall be capable of surviving a shock of
2000g over a frequency range of 100 - 10,000 Hz.
Vibration
- Samples shall be subjected to vibration at 46.4Grms
Random for 3 minutes in each axes.
Temperature Life
- Test condition 240 hours test, temperature 100°C.
Mating Durability
- Connector pairs (plug-adapter-plug) shall be tested
for mating durability for total of 500 mating cycles.
Bulkhead Adapter
- The bulkhead adapter shall be designed such that
the fiber interface of the internal connector plug can
be cleaned conventionally without disconnecting the
plug. It’s a 2-piece cleanable adapter.
Alignment Sleeve
- The alignment sleeve shall be a split-sleeve
configuration made from ceramic zirconia.
AVIM Performance
Insertion Loss
120
100
80
60
40
20
Insertion Loss [dB]
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0.
5
M
or
e
0.
45
0.
4
0.
35
0.
3
0.
2
0.
25
0.
15
0.
1
0
0.
05
Number of Connectors
Loss Results for 500 Connectors
AVIM Performance
Return Loss
Number of Connectors
Return Loss of 500 Connectors
450
400
350
300
250
200
150
100
50
0
50
52
54
56
58
60
62
Return Loss [dB]
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64
66
68
70
AVIM Performance
Thermal Cycling
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Cleanable Bulkhead
Mating Adapter: Wt. 7.3g, Length 24.4mm
PANEL MOUNT
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Re com m e nde d Pane l Cutout
Sealed Cleanable Bulkhead
D-624
Series
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Helium Leakage
Test on Bulkhead Adapter
Test Bulkhead Feed through for pressure leakage
 5 Connector Samples tested
 Tested into 1.0 x 10-3 TORR
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Typical leakage rate: < 5 x 10-3 cc/min. Helium
The bulkhead adapter is suitable for pressurized hull penetration!
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AVIM Performance
Durability Test for 500 Matings
AVIM Durability Test for 500 matings
Insertion Loss [dB]
0.00
-0.20
-0.40
-0.60 1
-0.80
-1.00
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101
201
301
401
501
AVIM Performance
Temperature Cycling
Plot for connector serial number: 14254
Deviation (dB)
0.5
0.3
0.1
-0.1
-0.3
-0.5
0
2
4
6
8
10
12
14
16
18
20
22
14
16
18
20
22
Time (hrs.)
Temperature Plot
Degrees C
140
90
40
-10
-60
0
2
4
6
8
10
12
Time (hrs.)
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AVIM Performance
Vibration Tested to 46.4Grms
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Random Frequency from 20Hz to 2’000Hz
0.5
0.3
#1
#2
0.1
#3
-0.1
00
:0
3:
08
00
:0
3:
38
00
:0
4:
08
00
:0
4:
38
00
:0
5:
08
00
:0
5:
38
00
:0
6:
08
00
:0
6:
38
00
:0
7:
08
00
:0
7:
38
00
:0
8:
08
Optical Change [dB]
Vibration Test Optical Stabiliy
-0.3
-0.5
Time [min]
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#4
#5
#6
Vibration Test
Failed Vibration Test
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Passed Vibration Test
No observable fretting
Solution to Vibration Problem
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Polish Analysis
on all Flight Critical Connectors
Radius of Curvature:
13.85mm
Fiber Spherical Height: 0.047µm
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Linear Offset (µm)
17.1µm
APC Polish Angle:
7.988°
AVIM Connector
RF Shielding Test Results
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Test performed from 200MHz to 18GHz
Test determines the RF attenuation through the Bulkhead
Shielding is better than 60dB from 200MHz to 5.8GHz
Shielding from 5.8GHz to 18GHz was measured at better than
30dB but Test Equipment limited.
The Cleanable Bulkhead Adapter is specifically designed to provide excellent RF attenuation.
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RF Shielding Effectiveness Test
© DIAMOND SA / 03-01 / 21
RF Shielding Effectiveness Test
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