The Progression of Connector Technology from Defense > Motorsport > UAV/Autonomous Vehicle Applications

The Progression of Connector Technology from Defense > Motorsport > UAV/Autonomous Vehicle Applications

Over the past fifty years, interconnect technology has not only advanced greatly but has allowed for multiple paths of improvement to parts originally released in the 1970's for defense and aerospace applications.

The Deutsch Autosport & Souriau 8STA catalogs largely based their 'standard' offerings from the MIL-DTL-38999 connector series brought to market by Amphenol Aerospace.

The standard catalog MIL-DTL-38999 Series I connectors were improved by Deutsch and Souriau by enhancing the standard product offerings by way of dropping down a shell size, integrating a knurled backshell that did not require a threaded accessory to be added to accept a boot, adding a conductive black zinc finish, up to seven different keyways in some series with visual identifiers (color bands on the connector), and smaller overall packaging of plugs and receptacles. All of these contributed to the inevitable design and release of even smaller, lighter, and more motorsport specific solutions for the demands of one of the harshest environments in the world.

It's somewhat ironic that motorsport began using what defense was to achieve the goal of lasting long enough to finish a race and now the tables have turned with defense, UAV, drone, and other markets utilizing motorsport connectors solely due to the technology improvements seen in the past ~30 years.

At one point in time, the MIL-DTL-38999 Series 1 'smallest' connector was a Size 9 Shell, measuring 21.4mm W x 31.mm L which was surpassed by:

Deutsch Autosport

• Deutsch ASL, Size 6 Shell 5-Way          15mm W x 19.3mm L
• Deutsch ASU, Size 3 Shell 3/5-Way      12.5mm W x 18.5mm L
• Deutsch ASX, Size 2 Shell 3/5/6-Way   10.3mm W x 18.05mm L 
• Deutsch ASX Size 1 Shell 4-Way           9.80mm W x 17.50mm L
  • To Be Released

Souriau 8STA

• Souriau's Size 4 Shell 3/5/6-Way           13.6mm W x 18.55mm L
• Souriau's Size 2 Shell 3/5/6-Way           10.6mm W x 16.3-17.6mm L
• Souriau's Size 1 Shell 3/5-Way               8.6-9.55mm W x 16.3-16.7mm L   

The never ending pursuit of weight and space savings and the old adage of 'Smaller, Lighter, Faster' has propelled each manufacturer in various sectors to gaining market position for de facto standard solutions specific to different forms of motorsport. If you're working on race cars in the US, you'll often see heaps of Deutsch ASL and ASU used throughout vehicle designs. In Europe, Souriau 8STA has maintained a strong hold on the market and with their ever popular Size 1 connectors originally offered in a 3-position and now being even readily available in a 5-position planform, the applications we are placing them in are limitless.

With the obvious being motorsport, we have supplied these connectors to various markets such as UAV and drone, medical, agricultural, defense, autonomous vehicles, robotics, aquatic, and even subterranean applications. The Souriau Size 1 Connector is the smallest removable crimp contact electrical connector in the world, it is entirely serviceable, and is virtually unchallenged in terms of it's technical features for such a small connector.

Souriau Size 1 Specifications

Shell                                  Aluminum Alloy
Shell Plating                     Conductive Black Size
Insulator                           Thermoplastic
Grommet/Seal                 Liquid silicone rubber
Contact                             Gold Plated Copper alloy
Contact Ampacity           3A
Endurance                       500 Mating Cycles
Shock                               Half sine mechanical shock, 50g/11ms
Vibration                         147m/s², 10 to 2000Hz
Contact Retention           20N Maximum
Test Voltage (Vrms)         400, Serivce R
Contact Resistance         <16 mΩ
Insulation Resistance       ≥ 5000MΩ @ 400Vdc
Operating Temperature  -55°C to +175°C (-67°F to +347°F)
Sealed Mated Rating       IP67
Salt Spray                         48 hours

Considering the ever increasing technology found in applications in all of these markets, size and weight will always be key performance factors. These connectors accept 24AWG-30AWG wire and are a perfect solution for the connection of low draw power supply, sensing equipment, communication protocols, and programming access.

Whether we are using hundreds internally for single production runs or supplying thousands to programs all over the world in a wide array of applications, when it comes to connector technology there is a noticeable disparity in what certain applications and their markets are accustomed to choosing for the projects. 

Whether it flies or drives, is part of a hive mind, functions above or below ground, or lives in a harsh environment that holds zero tolerance for failure, allow Race Spec to place you with a lighter, smaller, serviceable, easier to assemble, and superior connector solution for your project today. These can be specified for assembly within our build-to-print service offerings or supplied at volume worldwide.

Take a look at the Size 1, Size 2, and Size 4 offerings from Souriau here!