245 Lynnfield Street Peabody, MA 01960-5099, USA Tel. 978.532.0775 Fax 978.531.6993 www.trucorporation.com TRU MEIATM Products Mating Durability Test Report Objective Test & characterize the mating durability of TRU MEIATM Products (MEIA-1625 & MEIA-875) over an extended number of mating cycles to simulate the lifetime performance of TRU MEIA interface(s). The test will measure and monitor the following parameters: VSWR, insertion loss, phase, coupling torque, and insertion withdrawal forces to determine their impact on electrical/ mechanical performance. A separate test; insertion / withdrawal force will be measured to determine the effect over an extended number of mating cycles to simulate the lifetime performance of MEIA interface(s). Test Samples One (1) each cable assembly described below was subjected to the test. Sample 1: MEIA-1625 Cable Assembly: 13.75” length, TRU-920 cable, Fig 1-3 Connector 1: MEIA-1625 (f) Jack, Right Angle Connector 2: MEIA (m) Plug Adapter 1: 7-16 (f) to 1 5/8 EIA (f) plus 1 5/8 EIA (m) to MEIA-1625 (m) Adapter 2: 7-16 (m) to 1 5/8 EIA (f) plus 1 5/8 EIA (m) to MEIA-1625 (f) Sample 2: MEIA-875 Cable Assembly: 13.5” length, TRU-450 cable, Fig 4-6 Connector 1: MEIA-875 (f) Jack, Right Angle Connector 2: SC (m) Plug Adapter 1: 7-16 (f) to 7/8 EIA (f) plus 7/8 EIA (m) to MEIA-875 (m) Adapter 2: SC (f) to 7mm TEST SAMPLE 1 MEIA-1625 Assy. Adapter 1 Adapter 2 Cable assembly Figure 1 1 5/8 (m) to MEIA-1625 7-16 (f) to 1 5/8 EIA (f) MEIA-1625 right angle connector Figure 2 MEIA-1625 (f) to 1 5/8 (m) 1 5/8 EIA (f) to 7-16 (m) MEIA-1625 (m) connector Figure 3 MEIA-875 Assembly Adapter 2 Adapter 1 Cable Assembly Fig 4 7/8 EIA (m) to MEIA-875 (m) 7-16 (f) to 7/8 EIA (f) MEIA-875 right angle connector Fig 5 SC (m) connector SC (f) to 7mm Fig 6 Test & Inspection Conditions: All individual tests and inspections performed under the following conditions unless otherwise specified in the detail procedure(s): Environment: Temperature: Relative Humidity: Barometric Pressure: Room Ambient, 59 to 86 deg F (15 to 30 deg C) 20% to 80% Sea Level (650 to 800mm Hg) Configuration: Tests and inspections will be performed on a clean flat surface (bench or equivalent) in a clean well-lighted area, free of debris and foreign objects, unless otherwise specified. Test & Inspection Equipment: The following test equipment / tools / fixtures or equivalent were used to perform the test & inspections. Electrical: (Fig 10) Vector Network Analyzer (HP 8753E) used on all electrical measurements Applicable test port cables / adapters for each assembly, set up as applicable per figures 1-9 7-16 Calibration Kit (p/n: Maury Microwave 2750B) Full 2 Port Calibration: 401 data points 30 Hz BW S11 measurement = End 1 of cable assembly (right angle connector) S22 measurement = End 2 of cable assembly (straight connector) Electrical Test Set-Up S11 S22 Network Analyzer Device Under Test Fig 7 Mechanical: (Fig 8, 9 & 10) Force Gauge: Chatillon DFE-100 Used on MEIA-1625 and MEIA-875 contacts per figure 8. Torque Meter(s): CDI Torque Products: 751DIN, 3002LDIN per figure 9-10. Stereo Magnifying Scope: (Vision Engineering p/n) Digital Height Gauge: Fowler-Trimos V300+ Mechanical Test Set-Up Torque Meter Torque Meter Force gauge MEIA-875 Contacts MEIA-1625 Fig 8 Fig 9 Fig 10 Test Procedure: • Baseline electrical / mechanical tests were performed on each of the sample assemblies: o VSWR, Insertion Loss, Phase o Insertion & Withdrawal force o Interface Dimensions, Visual Examination of Product • Subject each sample to 500 mating cycles or until a failure occurs. o Note: a cycle consists of 1 complete electro-mechanical mating onto its corresponding mating adapter or mating contact and 1 complete un-mating from its corresponding adapter or mating contact. o Coupling torque for MEIA-1625: 165 in-lbs o Coupling torque for MEIA-875: 70 in-lbs • After every 25 cycles (up to 100), then every 50 (up to 500) all electrical / mechanical test & inspections performed at baseline were repeated on each sample. The test results were summarized and recorded per the following data: MEIA-1625 TEST DATA Withdrawal Force MEIA-1625 10.0 10.0 9.0 9.0 8.0 8.0 7.0 7.0 Force (lb) Force (lb) Insertion Force MEIA-1625 6.0 5.0 4.0 6.0 5.0 4.0 3.0 3.0 2.0 2.0 1.0 1.0 0.0 0.0 0 50 100 150 200 250 300 0 50 100 Mating Cycles 150 200 250 300 Mate Cycles f Typical VSWR MEIA-1625 1.20 Typical Insertion Loss MEIA-1625 1.18 0.000 1.16 -0.050 Insertion Loss (dB) 1.14 VSWR 1.12 1.10 1.08 1.06 1.04 1.02 -0.100 -0.150 -0.200 -0.250 -0.300 -0.350 1.00 -0.400 0 50 Freq: 0.3 MHz - 1.5 GHz 100 150 Mating Cycles 200 250 300 0 50 Freq: 0.3 MHz - 1.5 GHz 100 150 Mating Cycles 200 250 300 MEIA-875 TEST DATA Withdrawal Force MEIA-875 12.0 12.0 10.0 10.0 8.0 8.0 Force (lb) Force (lb) Insertion Force MEIA-875 6.0 6.0 4.0 4.0 2.0 2.0 0.0 0.0 0 50 100 150 200 250 300 350 400 450 500 0 50 100 150 Mating Cycles 250 300 350 400 350 400 450 500 Mating Cycles Typical Insertion Loss MEIA-875 Typical VSWR MEIA-875 0.000 1.90 -0.100 1.80 -0.200 1.70 -0.300 Insertion Loss (dB) 2.00 1.60 VSWR 200 1.50 1.40 1.30 -0.400 -0.500 -0.600 -0.700 1.20 -0.800 1.10 -0.900 1.00 0 50 100 150 Freq : 0.3 MHz - 3.0 GHz 200 250 300 Mating Cycles 350 400 450 500 -1.000 0 50 100 150 Freq : 0.3 MHz - 3.0. GHz 200 250 300 Mating Cycles 450 500 PHASE CHANGE TEST DATA MEIA-1625, MEIA-875 Phase Change 10.0 8.0 MEIA-1625 6.0 MEIA-875 Phase (degrees) 4.0 2.0 0.0 -2.0 -4.0 -6.0 -8.0 -10.0 0 50 100 150 200 250 300 350 400 450 500 Mating Cycles Freq: .3 MHz - 3.0 GHz Results / Conclusions: • TRU MEIA-1625 products meet /exceed 250 mating cycles, without any degradation to electrical / mechanical performance parameters. • TRU MEIA-875 products meet /exceed 500 mating cycles, without any degradation to electrical / mechanical performance parameters. • The surface of the interface(s) exhibited wear marks and some plating wear over the threads (see figures 11-14). • Recommended mating torque: MEIA-1625 165 in-lbs +/- 15 in-lbs MEIA-875 70 in-lbs +/- 10 in-lbs • The insertion/ withdrawal forces: Insertion MEIA-1625 5-10 lbs MEIA-875 3-9 lbs Withdrawal 4-9 lbs 2-8 lbs Wear marks Plating worn off threads Fig 11 Fig 12 Wear marks Plating worn off threads Fig 13 Fig 14