Avionics Connector Segmentation for Signal Integrity
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Solution Overview
Problem
Existing avionics system interfaces, such as breakout boxes, often suffer from signal degradation due to the mixing of incompatible signal types and electromagnetic interference, and the use of long jumpers introduces additional disconnect points that further degrade signal integrity during testing.
Innovation Solution
A quick-disconnect cable harness signal break-out adapter with a center portion featuring pin-insert and/or pin-out connectors or a removable clasp-type adapter ring, which provides access to individual signals with minimal signal line interruption and electromagnetic interference, maintaining signal integrity by reducing the length of extension wires and shielding against external influences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a breakout box with long jumpers is used to test signals, then signal access is provided, but signal integrity is degraded due to electromagnetic interference and multiple disconnect points
Solution Approach 1:
The electrical connector is divided into distinct segments: a first pass-through connector for wire harness connection, a second pass-through connector for bulkhead connector connection, and a center portion with electrical connection points. This segmentation allows signal access without requiring long jumpers, as each segment performs a specific function and maintains signal integrity through direct connections.
Solution Approach 2:
The center portion of the electrical connector acts as an intermediary element between the wire harness and bulkhead connector. It provides electrical connection points that enable testing equipment to access signals without introducing long jumpers or multiple disconnect points, thereby maintaining signal integrity while facilitating easy access.
2Ease of manufacture
If metallic breakout box without individual signal shielding is used, then manufacturing is simplified, but electromagnetic interference between signals increases
Solution Approach 1:
The electrical connector provides individual signal shielding for each electrical connection point in the center portion, rather than using a single metallic enclosure. This local quality approach shields each signal individually from electromagnetic interference while maintaining manufacturing feasibility through modular construction and standard shielding materials.
Data Source
AI summary
An electrical connector includes a first pass-through connector, a second pass-through connector, and a center portion coupled between the first pass-through connector and the second pass-through connector. The center portion includes a plurality of electrical connection points on an exterior surface of the center portion. The electrical connector also includes a plurality of pass-through wires extending from the first pass-through connector to the second pass-through connector through the center portion, wherein the plurality of electrical connection points are electronically coupled to the plurality of pass-through wires.