© diamond sa / 03-01 / 1 diamond avim connector fiber optic connector for aero-space applications

© DIAMOND SA / 03-01 / 1

DIAMONDAVIM Connector

Fiber optic connector for aero-space applications

© DIAMOND SA / 03-01 / 2

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

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 CoreIL less than <0.5dBRL better than 55dB

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

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

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.

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).

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.

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Loss Results for 500 Connectors

0

20

40

60

80

100

120

Insertion Loss [dB]

Nu

mb

er

of

Co

nn

ec

tors

AVIM PerformanceInsertion Loss

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AVIM PerformanceReturn Loss

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AVIM PerformanceThermal Cycling

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Recommended Panel CutoutPANEL MOUNT

Mating Adapter: Wt. 7.3g, Length 24.4mm

Cleanable Bulkhead

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D-624Series

Sealed Cleanable Bulkhead

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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

Typical leakage rate: < 5 x 10-3 cc/min. Helium

The bulkhead adapter is suitable for pressurized hull penetration!

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AVIM PerformanceDurability Test for 500 Matings

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Plot for connector serial number: 14254

-0.5

-0.3

-0.1

0.1

0.3

0.5

0 2 4 6 8 10 12 14 16 18 20 22

Time (hrs.)

De

via

tion

(d

B)

Temperature Plot

-60

-10

40

90

140

0 2 4 6 8 10 12 14 16 18 20 22

Time (hrs.)

De

gre

es

CAVIM Performance Temperature Cycling

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Vibration Test Optical Stabiliy

-0.5

-0.3

-0.1

0.1

0.3

0.5

Time [min]

Op

tical

Ch

ang

e [d

B]

#1

#2

#3

#4

#5

#6

AVIM PerformanceVibration Tested to 46.4Grms

Random Frequency from 20Hz to 2’000Hz

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Failed Vibration Test Passed Vibration TestNo observable fretting

Vibration Test

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Solution to Vibration Problem

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Radius of Curvature: 13.85mm

Fiber Spherical Height: 0.047µm

Linear Offset (µm) 17.1µm

APC Polish Angle: 7.988°

Polish Analysis on all Flight Critical Connectors

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AVIM Connector RF Shielding Test Results

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

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RF Shielding Effectiveness Test