Backshell Tooling for Military & Aerospace

BETA® Backshell Accessory Tools

The evolution of circular connectors has produced a multitude of configurations which have more precise dimensional tolerances and electrical characteristics than any other mechanical component used in modern electrical systems. The associated tooling must meet the same level of precision to apply the connector to its intended purpose. Until now, very little attention has been focused on the tooling which is used to mount strain-relief backshells and other accessories to wired connector assemblies. This is why the BETA®system was developed.

ADAPTOR TOOLS

This unique concept is based upon adaptor tools which are configured to mate with a specific connector series and shell size regardless of keying arrangement. These adaptors may be used simply as hand holding devices for easy tightening, or, for more exact requirements, with other DMC BETA® tools.

SIMPLE HAND TIGHTNING

                   Strain relief, connector, adaptor.

In the most basic operation, the adaptor is mated with the connector, and held in one hand.  this stabilizes the connector while the backshell accessory is tightened with the other hand.

SIMPLE MECHANICAL ASSIST

Soft Jaw Pliers, Strain relief, connector, adaptor, 

T-handle

When mechanical assistance is necessary to sufficiently tighten the accessory onto the connector, the stabilizing effect of the adaptor can be reinforced with one of several tools — in the operation shown, the connector is held stationary by the use of a “T” handle in the drive hole of the adaptor, while soft jaw pliers are being used on the accessory.

NOTE:  Rotating the connector is not recommended — due to the stress which it imposes on the wire, contacts and sealing components.  Adaptors and their associated tools that are designed to hold the connector stationary while the backshell accessory is turned

PRODUCTION STATION APPLICATIONS

Static Torque Meter, Adaptor Tool, Connector, 

Strain Relief, Strap Wrench

When the measurement of torque is a requirement of a particular cable assembly operation, this can be easily accomplished with the use of the static torque meter.  The adaptor is attached to the square drive on the torque meter, and this arrangement holds the connector while the backshell accessory is torqued onto the connector, with a strap wrench.  When the torque reaches the value set on the dial, a signal light advises the operator that the desired torque value has been applied.
When optimum repeatability and production efficiency demand, the assembly station vise can be used to complement the ability of adaptor tools to stabilize the connector.  As shown, the vise is being used to firmly hold the connector.adaptor tool, while a strap wrench is being used to tighten the backshell onto the connector

PRODUCTION STATION APPLICATIONS (cont)

On multi-piece backshell, the correct torque on each accessory can only be achieved by efficiently holding adjacent parts.  In the example shown, the assembly station vise is being used to hold the backshell segment already torqued onto the connector, while the strain relief is tightened with a strap wrench and a torque meter.  Thus, the correct torque can be applied to the backshell segments without affecting the torque value already applied to prior connector/accessory components.

CONNECTOR MATE® ASSEMBLY VISE

The circular connector vise is unique in design. It utilizes a set of jaw inserts which accommodate diameters from 3/8″ to 2″. The V-shaped inserts may be mounted on any of 12 keyed positions to grip the work piece in the most beneficial orientation. No finish damage or distortion will occur to the connector or accessories because the jaw inserts are molded of durable polyurethene. These are supplied in a convenient set box along with a vise key and ratchet drive tool.

STRAP WRENCHES

Strap wrenches which are commercially available for general purpose duty usually have shortcomings when applied to the production or maintenance demands of circular connector work. That was the design consideration of the exceptional strap wrenches offered by DMC. Various strap widths are available from 5/15″ to 1″ and gripping diameters from 1/2″ to 4″, the model having 2 1/4″ maximum diameter being the most popular.

JAM NUT SOCKETS

Jam Nut Socket tools have been developed specifically for the installation of Jam Nut receptacle connectors. They are available in a durable machined aluminum series and a versatile composite construction, which is an excellent choice for OEM assembly areas due to their light weight, and the non-marking surfaces. The traditional “General Purpose” formed steel sockets are great for non-torque specific jam nut applications.

ACCESSORIES

The product line is complemented by a variety of accessories which allow the user mount and use this system in the most comparative positions with all types of circular connector applications. All are available in MIL-SPEC type kits or as individual components for all currently manufactured connector specifications. A detailed brochure is available upon request.

To obtain a quotation or explore the range of Beta Backshell Accessories, please click on the following link