EMI Filter Fabrication
Aware of Captor Corp’s expertise in electromagnetic interference, a customer contacted us for fabrication & design of a custom EMI filter.
This filter needed to handle AC and DC power and signal lines for a systems application designed for aerospace and military uses. We worked with the customer to create a filter with operating voltages and currents of 115 VAC, 3-phase, 400 Hz, 4 amps; 270 VDC, 12 amps, 2 lines; 5 VDC, 500 mA for 14 signal lines. Input termination is a D38999 military connector and the output is a M24308 military D-sub connector. The filter measured 7.00″ x 4.00″ x 5.00″, weighed 6 lb, and had operating temperature of -55° to +105°C and non-operating temperature of -55° to +125°C. The chassis was constructed of cold rolled steel with electro tin-lead plated finish and threaded inserts for mounting. We performed full electrical and environmental testing to ensure proper functionality.
The following table details this EMI filter fabrication project, including all testing standards that were met. For additional inquiries, please feel free to contact us.
EMI Filter Fabrication Highlights
Capabilities
Filters AC power lines, DC power lines, and signal lines for system application.
Operating Voltages and Currents
115 VAC, 3 phase, 400 Hz, 4 amps
270 VDC, 12 amps, 2 lines
5 VDC, 500 mA for 14 signal lines
Electrical Testing Performed
Insertion Loss: MIL-STD-220
DWV: MIL-PRF-15733 4.6.5 and MIL-STD-202, Method 301
Insulation Resistance: MIL-PRF-15733 4.6.7 and MIL-STD-202, Method 302, Test Condition A
Capacitance: MIL-PRF-15733 and MIL-STD-202, Method 305
Voltage Drop: MIL-PRF-15733 4.6.8
Burn-In at rated voltage and current
Environmental Testing Performed
Vibration: MIL-PRF-15733 4.6.17.2 and MIL-STD-202, Method 204, Test Condition D
Shock: MIL-PRF-15733 4.6.16 and MIL-STD-202, Method 213, Test Condition C
Thermal Shock/Cycling: MIL-PRF-15733 and MIL-STD-202 Method 107, Test Condition A
Humidity: MIL-STD-202, Method 103, Test Condition B
Altitude: MIL-STD-202, Method 105, Perform DWV and IR
Input Termination
D38999 Military Connector
Output Termination
M24308 Military D-Sub Connector
Overall Part Dimensions
7.00 x 4.00 x 5.00 inches
Estimated Part Weight
6.0 pounds
Operating Temperature Range
-55° to +105°C
Non-Operating Temperature Range
-55° to +125°C
Chassis Material
Cold Rolled Steel
Chassis Finish
Electro Tin-Lead Plated
Mounting
Threaded Inserts
Industry for use
Aerospace, Military
Standards met
MIL-STD-461, Customer supplied specification, AS9100 quality system, ANSI/IPC-A-610 Class 3 workmanship