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DIAMOND AVIM Connector. Fiber optic connector for aero-space applications. AVIM Connector. The AVIM connector family, is designed to be used in high reliability space and aerospace programs.
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DIAMONDAVIM Connector Fiber optic connector for aero-space applications
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.
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
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 • 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.
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.
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.
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. Specifications
Mating Adapter: Wt. 7.3g, Length 24.4mm Cleanable Bulkhead
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!
AVIM PerformanceVibration Tested to 46.4Grms • Random Frequency from 20Hz to 2’000Hz
Vibration Test Failed Vibration Test Passed Vibration Test No observable fretting
Polish Analysis on all Flight Critical Connectors Radius of Curvature: 13.85mm Fiber Spherical Height: 0.047µm Linear Offset (µm) 17.1µm APC Polish Angle: 7.988°
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.
