How do D38999 series connectors accommodate different wire sizes and types?
How do D38999 series connectors
MIL-DTL-38999 series connectors accommodate many different wire sizes and types. They’re often used in harsh environments where they must withstand shock and vibration, temperature extremes, and exposure to corrosive chemicals like salt spray. They must also be able to easily connect and disconnect. That’s why engineers choose these high-reliability connectors—also known as mil spec connectors—to design their products.
As a result, these QPL-approved connectors are used in military aerospace applications, but they’re also found in a variety of other rugged applications, including marine electronics, communications equipment, weapons systems, armored aircraft carriers and tanks, medical instrumentation, and test equipment. Engineers and procurement professionals in both civil and military aerospace use these QPL-approved connectors on a daily basis, but sometimes they can forget the basics, like how they’re designed to handle differing wire sizes and types.
To address this issue, TE offers a wide range of options for the popular D38999 series connectors line. These include a variety of body styles, contact terminations, and shell materials—from aluminum to stainless steel to composite—along with a selection of finishes. In addition to the standard breech-lock coupling, there are other options for connecting and disengaging the connectors, such as a quick disconnect coupling mechanism and a push-pull latching system.
How do D38999 series connectors accommodate different wire sizes and types?
The aluminum shells of these connectors are available in a number of different plating and finishing options, including black zinc nickel, olive green cadmium, and nickel—along with hard anodized and passivated finishes. These finishes can help resist corrosion and improve the appearance of the connectors in the harsh environments where they’re used. In addition, these shells are polarized to ensure proper orientation of the mating halves prior to electrical engagement, which helps prevent mismating and reduce wear and tear on the contacts.
These connectors come in a variety of shell types, from front and rear-mount square flange receptacles to in-line receptacles and jam nut receptacles, and plugs that are either straight or right angle. They can be mateable with each other or with other compatible connectors, such as those in the Series 1 bayonet and ETV 38999 families of connectors.
Another way that these connectors can be customized is through the use of accessories such as cable savers, storage receptacles, and jam nuts. These accessories can help protect the connectors from damage caused by repeated mating cycles and prevent costly repairs, which is important in harsh environments where connectors may be exposed to a lot of vibration.
Lastly, these connectors can be modified to meet specific application requirements through the use of different insert arrangements. These inserts can add a number of features, such as high-voltage contacts for power and high-speed data. They can also be made to meet more stringent environmental standards, such as those for deep space or frigid temperatures.
These modifications and upgrades are all part of a group of connectors that TE refers to as “38999 specials.” While these specialty connectors are not a part of a particular product line, they can be developed for individual customers to solve unique engineering challenges. The 38999 specials are quickly evolving at TE, with new designs being added frequently. For example, the company recently released a scoop-proof MIL-DTL-38999 Series 3 connector that’s rated higher than standard qualified D38999/26 plug connectors and has high vibration performance.
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