Three-terminal integrated voltage regulator

With the rapid advancement of science and technology, this paper aims to provide an in-depth exposition of Methods for Selecting Aviation Connectors , its applicable scenarios, and the advantages it offers compared with existing domestic counterparts.

Aviation connectors can be classified in various ways. Based on frequency, they are divided into high-frequency and low-frequency aviation connectors; based on physical form, the main type is the circular connector; and based on application, they include cabinet-mounted aviation connectors, audio equipment connectors, power connectors, and special-purpose connectors.
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In electronic systems, the importance of aviation connectors is often underestimated. Many system designers have encountered situations where selecting the lowest-cost aviation connector ultimately results in higher total costs. Improper selection or use of aviation connectors can lead to system malfunctions, product recalls, product liability lawsuits, PCB damage, rework and repairs, and other issues—all of which can result in lost sales and customer churn. Therefore, during the product design phase, the critical role of aviation connectors should never be overlooked; otherwise, small oversights may escalate into significant problems that are difficult and costly to rectify afterward. It is thus evident that choosing the right aviation connector for electronic devices is of paramount importance.

So, how should aviation connectors be selected? Given the impact of the economic environment, cost considerations must be factored into the design process; however, even greater emphasis should be placed on product quality and high reliability, as well as the inherent design characteristics of the aviation connector itself. Below, drawing on ERNI’s innovative connector designs, we offer several recommendations for electronic designers:

First, the dual-rod design concept. This concept is integral to the ERNI aviation connector series. To put it visually, the dual-rod design achieves “killing two birds with one stone.” It features an optimized terminal design that accommodates high-speed signal transmission while offering greater alignment tolerance. When compared in terms of inductance, capacitance, and impedance, the dual-rod terminal structure is more compact than box-type terminals and is specifically optimized for high-speed applications to minimize signal discontinuities. The dual-rod design allows multiple aviation connectors to be mounted on the same circuit board without risk of mating difficulties or short circuits, as each individual connector does not need to carry a large number of signals. The streamlined dual-rod routing helps save space and enables the miniaturization of aviation connectors. Welding It also simplifies pin detection. For example, a single board can accommodate up to 12 connectors. At the same time, this design helps reduce rework costs. Typical applications include telecommunications end-user equipment and similar products.

Second, a lead-free bending assembly process. Traditional stamping processes can inadvertently cause lead bending or deformation due to improper handling, and the bending operation is prone to inducing microcracks—conditions that are undesirable from the perspective of long-term product reliability and may also compromise circuit performance and increase costs. ERNI employs a direct-stamping corner-bending process, which eliminates microcracks caused by bending in stamped terminals and thereby ensures the integrity of the electromechanical connection. Lead coplanarity reaches 100%, with tolerance controlled within ±0.05 mm, and 100% surface-mount lead coplanarity inspection guarantees reliable PCB assembly, facilitates excellent soldering, boosts first-pass yield, and reduces costs. In addition, this design enhances the structural robustness of right-angle aviation connectors, preventing damage from improper handling—making them virtually “unbreakable.” This design is particularly well suited for applications such as inkjet printer controllers and interface modules.

Third, high retention in surface-mount design. It is commonly believed that surface-mount components exhibit weaker board retention compared with through-hole components. However, does surface-mount termination necessarily result in lower board retention than through-hole termination? The answer is not absolute. Through design optimization, board retention can be significantly enhanced. For example, combining soldering supports, microvia technology for surface-mount leads, and large solder pads can collectively improve retention. In fact, even input/output aviation connectors can be implemented with surface-mount leads. This design can be aptly described as “taking root upon landing.” Practical applications include designs for X-ray machines, ultrasound scanners, robotic Ethernet switches, and more.

Fourth, robustness design. This design is intended to ensure the structural reliability of the aviation connector while also permitting the use of flat-block crimping tools. The contact plates are securely mounted within the housing to enhance overall structural rigidity, thereby enabling more efficient manufacturing processes and higher production output. In short, it can be described as “as solid as a rock.” Specific applications include positron emission tomography scanners and embedded systems for rail transit vehicles.

Fifth, high-current and fine-pitch design. As automotive electronics and consumer electronics continue to trend toward miniaturization, it is essential to adopt a design philosophy that balances high current-carrying capability with fine-pitch layout.

Sixth, an advanced locking mechanism. ERNI employs a dual-lock design to meet diverse application requirements: the positive-lock design is tailored for high-vibration environments and is particularly well-suited for automotive and subway applications, while the friction-lock design is optimized for general vibration conditions. This dual-lock configuration provides redundant safety, ensuring connection reliability, and allows on-site cable disassembly—for maintenance or replacement—without the need for specialized tools. This design is ideal for products such as surveillance cameras and LED vehicle lights.

The terminal blocks used in aviation connectors are critical components for establishing electrical connections. As core electromechanical elements of electrical wiring, they are subject to extremely stringent specification and quality requirements; therefore, when selecting such components, priority should be given to their power-handling capability. Given that different countries employ non-uniform criteria for evaluating the power and performance specifications of terminal block products, engineers must clearly define the methods for testing and validating product performance data, rather than relying solely on information provided in datasheets.

In Europe, IEC standards determine a device’s rated current by monitoring the temperature rise of metallic conductors as current increases: when the temperature of the metal leads exceeds the ambient temperature by 45°C, that current value is designated as the rated or maximum current, and 80% of the maximum current is specified as the permissible operating current. By contrast, the U.S. UL standard defines the device’s nominal current rating as 90% of the current corresponding to a temperature rise of 30°C above ambient. Although these standards differ in their approach, it is clear that the temperature of the metallic conductor portion plays a critical role in practical applications. Industrial equipment typically operates in high-temperature environments of 80°C; if the temperature rise reaches 30°C or 45°C, the terminal block temperature may exceed 100°C. Certain materials—such as those used in compact-packaged devices—may not be able to meet thermal-management requirements; therefore, in actual use, the current carried by the terminal block must be significantly lower than its rated value.

As enterprises increasingly adopt terminal blocks manufactured in different countries, it is essential to first understand the differences among the standards adopted in each region to avoid placing undue burdens on product designers. For example, Europe uses a nominal-value-based measurement approach; in European component design, the operating current must be kept below this nominal value.

Secondly, when selecting wire terminals for aviation connectors, attention must also be paid to the termination technology. Currently, many termination methods employ through-hole connections, which require mechanical support to ensure stable electrical contact with the power planes on multilayer printed circuit boards. In addition to the connection method, the type of leads used to connect the terminal to the PCB should also be considered. Single-lead configurations are typically chosen, but multi-lead options are also available. Using multiple leads helps distribute current more evenly across the PCB traces, providing greater mechanical stability and improving solder joint reliability.

Finally, when selecting wiring terminals for aviation connectors, aesthetic considerations should be taken into account; a well-designed appearance can significantly enhance the product’s user appeal.

(Reference: Electronic Component Technology)