XC158 series-Circular Electrical Connector Manufacturers

What role does the hyperbolic wire spring jack play in the XC158 series circular electrical connector? What are its design principles and manufacturing processes?
The hyperbolic wire spring jack is a key component for achieving electrical connection in the XC158 series circular electrical connector. Its main functions are reflected in the following aspects:
Provide stable and reliable electrical connection: The design of the hyperbolic wire spring jack enables multi-point contact between the jack and the pin. This contact method not only increases the contact area, but also improves the uniformity and stability of the contact, thereby ensuring low loss and high reliability of the connector when transmitting current and signals.
Adapt to harsh environments: The application environment in military, aviation, aerospace and other fields is often very harsh, such as vibration, impact, high temperature, low temperature, humidity, etc. With its unique structure and material selection, the hyperbolic wire spring jack can maintain a stable electrical connection in these extreme environments, effectively preventing signal interruption or current fluctuations caused by poor contact.
Anti-misplugging and anti-blind plugging: The XC158 series circular electrical connector adopts a five-key positioning design and the special shape of the hyperbolic wire spring jack, so that the connector can be accurately aligned when plugged in, avoiding damage or performance degradation caused by plugging errors.
The design principle of the hyperbolic wire spring jack is mainly based on the following key points:
Hyperbolic geometry design: The contact surface of the jack adopts a hyperbolic shape. This design not only enables a closer contact between the jack and the pin, but also provides appropriate guidance and buffering when the pin is inserted, reducing the friction and wear between the pin and the jack.
Wire spring structure: The wire spring structure is used inside the jack. This structure enables the jack to produce a certain elastic deformation when subjected to external force, thereby maintaining a constant contact pressure with the pin. The wire spring structure can also effectively absorb vibration and impact energy, improving the stability and durability of the connection.
Material selection: The contact part of the jack is usually made of copper alloy with high conductivity and high corrosion resistance, and is silver-plated or gold-plated to improve the conductivity and corrosion resistance of the contact. The shell and insulator of the jack are made of high-strength and high-insulation materials to ensure the reliability and safety of the connector in harsh environments.
HENGLIAN uses advanced processing technology and quality control methods to manufacture hyperbolic wire spring jacks to ensure the high precision and high reliability of the products. The specific manufacturing process includes the following steps:
Material preparation: Select appropriate copper alloy materials according to design requirements, and perform precision cutting and processing to prepare the contact part and shell of the jack.
Wire spring manufacturing: Use precision spring manufacturing technology to process the wire spring into a shape and size that meets the design requirements, and heat treat it to improve its elasticity and durability.
Jack molding: Assemble the processed contact part and wire spring into the shell of the jack, and through precision machining and polishing, ensure that the contact surface of the jack reaches the hyperbolic shape and surface roughness required by the design.
Quality inspection: Perform comprehensive quality inspection on the manufactured hyperbolic wire spring jack, including dimensional measurement, electrical performance test, mechanical performance test, and environmental adaptability test, etc., to ensure that the product meets the design requirements and relevant standards.
Packaging and storage: The qualified hyperbolic wire spring sockets are packaged and marked, and stored in a dry and clean environment to prevent product performance degradation due to moisture, pollution or mechanical damage.
As a leader in the electrical connector industry, HENGLIAN's production capacity and technical level are in a leading position in the industry. The company not only has CNC production workshops, assembly workshops and supporting manufacturers, but also has more than 300 various mechanical processing equipment and testing equipment to ensure the high precision and high reliability of the products. The company has also passed a number of military qualifications such as GJB9001C-2017 National Military Standard Quality Management System Certification, as well as ISO 9001, ISO/TS16949 and other quality management system certifications, providing customers with reliable quality assurance.