Contact Walkout

For this test, a pin installed in the connector is crimped to a wire, and the wire is hung over a mandrel with a weight. The connector position relative to the mandrel then undergoes one hundred cycles, effectively stressing the installed pin. Two pins are tested per connector, and the pins in question must not […] Read more

Thermal Shock – Hermetically Sealed Connectors

The thermal shock test is applicable to hermetically sealed connectors. The connector undergoes successive cycles consisting of times submersed in hot and cold water baths. After cycling is complete the connectors are dried in a forced air oven, and to pass the examination, the connector must have sustained no damage detrimental to the operation of […] Read more

Shell Spring Finger Forces

Aerospace connectors are expected to withstand regular mating and unmating during maintenance, component replacement, etc. It is important that a connector be adequately secured when in use, but not so tightly mated as to hinder the ability to unmate for maintenance. The shell spring finger force test evaluates the force required to engage and separate […] Read more

Humidity Test

There are several locations in aircraft where electrical connectors are regularly subject to high humidity conditions. Even without high humidity conditions, thermal cycling can wear down connector seals and create paths for fluid ingress. The system level impact can vary from signal degradation to shorting and electrical arcing. This test examines a connector’s resistance to […] Read more

Shell to Shell Conductivity

Connector shell conductivity is critical for several types of applications. For example, harnesses that contain EMI sensitive circuitry are typically shielded and require good grounding and EMI protection as the signals pass through connectors. Often, this test is used after a thermal/environmental exposure cycle to determine performance after accelerated aging. For this test, a set […] Read more

Gauge Retention

Applicable test instruments, or test gauges, are installed in three randomly selected cavities in each connector. An axial load is applied to individual test gauges in both directions slowly until the maximum load is reached. The displacement of the gauge tool with respect to the connector is reported. Read more

Accessory Thread Strength

Assessing thread strength can yield vital data for how much stress a connector had endured. This is particularly important for connectors mounted in shock environments of aircraft. In the test, the mated connector is mounted as if in normal service to a rigid panel. After mating the plug and receptacle connectors, a torque is applied […] Read more

External Bending Moment

The external bending moment test evaluates a mated connector’s ability to maintain circuit continuity under physical bending. Improperly secured harnesses can place a strain on connectors, a particularly common occurrence in tight areas where perfect routing and strain relief are not possible. In this test, the connectors are mated with one mounted to a rigid […] Read more

Gauge Location

To ensure interchangeability between connectors, the mechanical configuration of connectors must remain consistent. The gauge location test verifies connector geometry. A standard test gauge (a test device shaped to particular dimensions) is installed in a connector cavity and the axial location of the front of the gauge is measured against a set reference location to […] Read more

Bayonet Coupling Pin Strength

Coupling components have the potential to undergo high mechanical stress as a result of poor clamping, heavy wire harnesses, and maintenance operations. The intention of the bayonet coupling pin strength test is to assess the strength of the pins in each of the couplings. For this test, a static 50-pound load is applied to the […] Read more

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