In the expansive landscape of the space industry, Winchester Interconnect is an indispensable partner, ensuring precision and reliability from conceptualization to the realization of space missions. Renowned for its flight heritage, Winchester has made significant contributions to iconic programs, including the International Space Station (ISS) and the Europa Clipper mission, where Winchester’s innovative solutions have proven integral to the success of these complex endeavors.
Beyond individual missions, Winchester's interconnect solutions and complex cable harnesses hold a prominent place on major launch vehicle platforms, showcasing the company's commitment to addressing the unique challenges posed by space environments and the demands of commercial space partners.
Pioneering RF Interconnects in the Realm of Space Engineering
Winchester’s flight heritage starts with the RF and Microwave product line, ideally suited to perform in the harsh environment of space and capable of supporting the growing Ka and Ku frequency bands. As well, Winchester’s RF line includes connectors that are designed specifically for the unique application challenges of space. As an example, Winchester’s engineers helped address the effects of multipaction in radio frequency assemblies by designing unique connectors that overcame the complications due to corona. Winchester’s broad portfolio of connector interfaces and extensive engineering experience resulted in connector designs that optimize performance, size, weight and power ratings.
Winchester also possesses extensive experience with vented RF connectors. These connectors play a vital role in managing pressure differentials between the connector's interior and the vacuum of space, preventing the detrimental effects of outgassing and enhancing overall signal integrity. Their design mitigates the risk of trapped air, reducing the potential for signal distortion or damage to sensitive electronic components. In the realm of space exploration, where precision is paramount, vented RF connectors emerge as a fundamental technology, contributing to the success of satellite communications and deep space missions.
NASA follows strict outgassing requirements to ensure the reliability and performance of materials used in space applications. The relevant standard for outgassing is NASA's "Low Outgassing" specification, documented in NASA's Handbook for the Selection of Polymer and Elastomer O-ring Seals for Aerospace Propulsion Systems (NASA-HDBK-STD-1839).
Key requirements include:
— Total Mass Loss (TML): The TML is the maximum percentage of a material's initial mass that can be lost through outgassing. For most applications, NASA typically requires materials with a TML of less than 1%.
— Collected Volatile Condensable Materials (CVCM): CVCM represents the maximum amount of outgassed material that can condense on surfaces at higher temperatures. NASA usually requires materials with a CVCM of less than 0.1%.
— Water Vapor Recovered (WVR): WVR specifies the amount of water vapor that can be released during outgassing. NASA typically requires materials with a WVR of less than 0.1%.
— Materials that meet or exceed these requirements are considered low outgassing and are suitable for use in the vacuum of space where outgassing could contaminate sensitive instruments or degrade the performance of spacecraft components. These standards aim to maintain the cleanliness and integrity of spacecraft systems during their missions.
Problem Solving at the Edge of Possibility
One of the hallmarks of Winchester's collaboration with engineers in the space industry is its adept problem-solving approach. The space domain presents a myriad of challenges, from the harsh environmental conditions to the extreme temperature swings systems and components are exposed to. Vital to the success of space exploration is the use of cryogenically cooled propellants, notably liquid Hydrogen, Nitrogen, Oxygen and Liquid Natural Gas (LNG).
The shock and vibration standards of Mil Standard 38999 covers circular, high-density, and rack-and-panel connectors widely used in aerospace and military applications. NASA has specific requirements for connectors, including NASA-STD-7001: NASA Applications Guide for Conducting Static, Seismic, and Shock Analyses in the Design and Test of Launch Vehicle and Payload Systems. While not specific to connectors, this NASA standard provides guidelines for conducting shock analyses in the design and testing of aerospace systems, which could include connectors. Lastly NASA-STD-8739.21: Workmanship Standard for Surface Mount Technology includes requirements for shock and vibration testing related to connectors using surface mount technology.
These standards provide a guideline for performance, but it is critical to refer to the project requirements unique for each mission.
Winchester’s Hermetic connectors and in particular the proprietary Ceramax™ technology have been tested in a variety of environments. In particular, Winchester’s Hermetic connectors have been thermal cycled to cryo temperatures required for liquid propellant. Winchester’s engineers have worked with customers to design hermetic multipin feedthroughs and hermetic RF connectors used to monitor fuel status and will be used on critical future space missions including in-space fuel transfer. The hermeticity of the Winchester Ceramax connectors has been confirmed after thermal cycling and is suitable for applications which must meet the shock and vibration requirements of NASA-STD-7001.
Reliability as a Cornerstone
The space industry demands a level of reliability that goes beyond ordinary standards. The consequences of failure are not only measured in financial terms but, more crucially, in the potential loss of invaluable scientific data or the failure of an entire mission. Winchester Interconnect recognizes the gravity of this responsibility and, as such, places reliability at the core of its mission. The company's emphasis on delivering connectors and cable assemblies that withstand the rigors of space reflects a commitment to engineering excellence.
The MIL-DTL-83513 standard governs Micro-D connectors, specifying their design, performance, and testing requirements. These connectors, known for their compact size and high-density pin configurations, align with the stringent demands of space missions where space is a premium.
The MIL-STD-1540 outlines the environmental testing procedures, including vibration and thermal cycling, ensuring Micro-D connectors can withstand the harsh conditions of space travel. Moreover, the MIL-STD-883 establishes guidelines for the microelectronic devices used in these connectors, emphasizing reliability in the challenging space environment.
Compliance with these MIL standards not only ensures the durability and functionality of Micro-D connectors but also contributes to the overall efficiency of spacecraft by meeting stringent size and weight requirements. As space exploration advances, reliance on standardized Micro-D connectors becomes integral to the success and longevity of space missions.
Winchester’s micro-miniature connectors bridge the gap between the requirements of the mission and the connectors that enable successful mission execution.
Accelerating Time-to-Market in the Cosmos
The space industry is characterized by a sense of urgency. From the conception of a mission to its execution, every moment counts. Recognizing this imperative, Winchester Interconnect takes pride in its role as a catalyst in bringing space designs to market swiftly. In an industry where timeframes are often constrained by launch schedules and mission windows, the ability to expedite the development and deployment of interconnect solutions becomes a strategic advantage.
Winchester's commitment to accelerating time-to-market is not merely about speed but also about precision. The company's engineers understand the intricate balance between efficiency and accuracy. By streamlining design processes, optimizing manufacturing workflows, and leveraging their experience in the space domain, Winchester empowers engineers to meet tight deadlines without compromising on the quality or reliability of their designs.
Empowering Space Missions: A Vision for the Future
Winchester Interconnect's impact on the space industry extends beyond solving immediate engineering challenges; it is about shaping the future of space exploration. The collaborative ethos between Winchester and space engineers fosters an environment of continuous innovation. As new missions, from Earth observation to deep space research, continue to emerge, Winchester stands as a reliable partner, ready to contribute its technical prowess to push the boundaries of what is achievable.
For more information and to learn more about the Winchester technologies that will enable your mission, visit winconn.com/space or email us at space@winconn.com
