We previously discuss here drone manufacturing program SMT challenges in EMS manufacturing factories, and the need for printed circuit boards (PCB) used in many drones requiring wider route trace spacing, since arc potential increases in lower pressure environments above 20,000 feet, where many drones perform.
Drone and UAS cables and assemblies: connectors
Meanwhile, during drone assemblies operations and placement and connecting of functional aerial systems inside drone enclosures, which are also subject to external and internal systems forces and changes to environments, drones designed with critical thinking applied, combined with planning against as many known and unforeseen challenges, can better insure drone performance to desired specs and drone market relevance, and marketplace longevity by designing in insurance in the manufacture and electronic assembly of drones – against mishaps on EMS manufacturing production assembly lines.
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Drone and unmanned systems manufacturing quality concerns
To help manage against this, and to improve production assembly efficiency when seating electronic cable connection and wire harness assembly terminals, secondary locking and power double lock (PDL) connectors offer some degree of insurance to drone quality and performance.
One way drone manufacturers can achieve this, among many other challenges facing drone manufacturers, is by choosing adequate connectors and robust cables and cable assemblies, and related electronics and corresponding systems connectors.
Some criteria many drone manufacturers consider, early on, so drone programs can easily move from the new product introduction (NPI) phase to volume manufacturing (without costly design iterations) pertaining to choosing connectors include, but are not limited to:
- Audible click upon contact, insuring contact is made within connector housing
- PDL (power double lock) connection
- Proper connector mating, with adequate guides or polarizing ribs
- Ability to withstand resin or conformal coatings
- Designed for power circuit applications
- Corrosion-resistant
- UL recognized, VDE approved, and CSA certified
For military or aerospace operations technology, a common connector, and one of the smallest, is the circular connector. Based on their size, weight, and power (SWaP) versatility, circular connectors can aid drone engineers in solving various challenges and, they come in various sizes, including subminiature, and include various coupling types such as breech-lock, bayonet, and threaded.
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Other connector suitability considerations might be based on drone operating environment or material and plating options, as well as connector seals able to withstand liquid or rain or gas penetration. Additional considerations might also include protection against humidity and dust, among other possible contaminants.
Drones, in general, are also subject to high vibration and often varying, and very harsh environments. Choosing the proper connector can be the difference between a system’s strong, or weak, link. More on connector suitability and drone manufacturing challenges can be found in our 20-page white paper, ‘Drone, UAV, UAS Program Sourcing of Contract Electronics Manufacturing Services (EMS) & RFQ Quote Management‘.
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