The methodology for reducing excessive wear on the connector of a module in an avionics system in vibration is presented in this paper. Because of space limitations and time constraints, we designed special test fixtures and techniques to monitor the module system. Traditional differential accelerometers were unsuccessful in determining the relative displacement between the male and female halves of the connector. As an alternative, we implemented an optical probe. The probe measures distance directly through the amount of light reflected off a surface. The data obtained using the optical probe enabled a determination that the maximum allowable displacement to reduce the connector wear was 0.0003 inch rms. Based on these results, we designed and tested hardware modifications, which resulted in the avionics unit surviving the vibration environment.

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