nicomatic, a leading provider of advanced interconnect solutions for unmanned aerial vehicles (UAVs), drones, and various aerospace and robotics applications, has published an insightful article highlighting the significance of current-carrying capacity, derating, and connector design in the context of nano-satellite technology.
Ensuring reliability in space missions is paramount,as rectifying failures post-launch is not an option. Given that even nano-satellites can incur launch costs in the thousands, a malfunction stemming from a subpar connector choice can lead to significant financial repercussions.
Satellite applications impose rigorous requirements on thier components, including size, weight, shock resistance, vibration tolerance, and the ability to withstand extreme temperatures. connectors serve a dual purpose by providing both electrical and physical connections, making it essential to conduct a comprehensive evaluation of the connectors selected for these applications. Miniaturization is vital to optimize payload capacity, and devices must be capable of executing multiple missions effectively.
Nano-satellites are compact, typically weighing under 500 kg, with some models being substantially lighter. For instance, Cubesats adhere to a standardized dimension of 10x10x10 cm and weigh merely 1.33 kg. Connectors are crucial components as they not only transmit signals or power but also physically link various system parts. Consequently, mechanical stresses on the connectors, alongside their electrical performance, must be thoroughly assessed. In space environments,connectors must endure intense shock and vibration during launch,and also extreme temperature fluctuations as the satellite transitions between sunlight and shadow.
The challenge lies in selecting a connector system that is both resilient and durable enough to withstand the harsh conditions of space while remaining lightweight and compact. While space-grade components are available, they frequently enough come with a hefty price tag. Conversely,Mil-Spec connectors frequently meet the requirements for satellite missions. Recent research conducted at the Space Center of the University of Grenoble indicates that a notable number of Cubesat (CSUG) failures can be attributed to poor connections.
Mathieu Barthelemy, director of the Grenoble University Spatial centre (CSUG), stated: “The current-carrying capacity of connectors utilized in nano-satellites and Cubesats is critical and can jeopardize the entire mission. In these projects, components are often sourced from commercial markets, making them more susceptible to current fluctuations.”
The current-carrying capacity of the connector’s signal or power pin is a fundamental specification that must be evaluated. This metric determines the maximum current that can safely flow through the connector contact. It is also essential to consider derating curves, which account for environmental and testing factors that may reduce the allowable current. Recently, Nicomatic collaborated with a client using CMM connectors with high-power contacts designed to handle 10A fast pulse currents and 3A for continuous operation. Nicomatic advised that the client could safely utilize lower-rated signal contacts, resulting in significant space savings.
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