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At Captor Corporation, we have an exceptional depth of experience in the electronic filter industry and the related field of military communications. For this project, we combined that with some good sourcing and assembly strategies to produce the electromechanical DC booster assembly highlighted here.

Due diligence enabled us to find a suitable vendor for casting the aluminum housing with consistent dimensional accuracy at high production rates. We also found a reliable source for applying a Mil-spec conversion coating and finishing the enclosure with an impact-resistant MIL-PRF-22750 paint, which provided numerous protections, such as to weathering, humidity, and chemicals.

The other components of this system were built in-house and assembled according to IPC-A-610 Class 3 workmanship standards. It featured five pairs of 28 VDC power lines, two pairs of 15 VDC power lines and high-speed Ethernet signal carrying capacity. Along with a DC-DC converter, capacitor bank for voltage storage, and multiple circuit cards, it incorporated custom internal wire harnesses and power line filters. We used D38999-type connectors on the single input, dual output terminations.

When completed, it measured 12.00″ in length x 5.00″ in width x 5.00″ in height, weighed 9 lbs., and was qualified to withstand operating temperatures in the -55°C to +80°C range. Its robust and rigorous operating specifications prompted us to build customized functional test equipment to ensure we met the demands of the customer specifications. After burn-in at rated voltages and currents, we used explicit MIL-STD-202 test methods to calculate dielectric withstand voltage, insulation resistance, and capacitance ratings, as well as vibration, shock, and thermal shock resistance.

If you are interested in learning more about this project, the table below provides more details, including the specific test methods that we used. Contact us at any time for more information – we welcome an opportunity to consult on your next project.

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Features

DC-DC Converter, Capacitor Bank for Voltage Storage, Multiple Circuit Cards, Internal Wire Harnesses, Filters DC power lines, and signal lines for system application.

Operating Voltages and Currents

28 VDC, 25 amps, 5 pairs
15 VDC, 10 amps, 2 pairs
High Speed Ethernet Signals

Electrical Testing Performed

Functional Test Equipment designed and manufactured to meet customers operating requirements.

DWV

MIL-STD-202, Method 301

Insulation Resistance

MIL-STD-202, Method 302, Test Condition A

Capacitance

MIL-STD-202, Method 305
Burn-In at rated voltages and currents

Environmental Testing Performed

Vibration: MIL-STD-202, Method 204, Test Condition D
Shock: MIL-STD-202, Method 213, Test Condition C
Thermal Shock/Cycling: MIL-STD-202 Method 107, Test Condition A

Input Termination

(1) D38999 Series Connector

Output Termination

(2) Separate D38999 Series Connector

Overall Part Dimensions

12.00 x 5.00 x 5.00 inches

Estimated Part Weight

9 pounds

Operating Temperature Range

-55° to +80°C

Non-Operating Temperature Range

-55° to +105°C

Chassis Material

Custom Aluminum casting

Chassis Finish

Chemical Conversion Coating in accordance with MIL-DTL-5541, Painted in accordance with MIL-PRF-22750.

Mounting

Mounting features within the casting

Industry for use

Army, Military

Standards met

Customer supplied specification, AS9100 quality system, ANSI/IPC-A-610 Class 3 workmanship, IPC/WHMA-A-620