Electric cable cost, size, and weight is a major concern for aerospace and military engineers. A cable comprises one or several wires that are bundled or run side by side. Connectors and a cable assembly comprise one or several electrical cables. Cable assemblies are not suitable for connecting devices. But, you can solder them onto electronic PCB assemblies. The following are four ways that connectors and cables prove vital to modern system designs.
Ongoing Upgrades
Many shipboard and airborne radars are being upgraded now. Olson, from TE Connectivity, believes that better solutions are required to perform successful system upgrades. Defense and aerospace organizations are upgrading systems to increase their capability. For instance, many Consolidated Afloat Networks and Enterprise Services (CANES) upgrades are using fiber-optic connectors and cables to send more data.
Such upgrades help the military with vital information. Some systems are combining communications, imaging, full-motion videos, and data. They handle video, perishable data, and satellite communications at the same time. Old MIL-DTL-38999 Series III connectors cannot perform such tasks. Cable engineers, performance engineers, and connector engineers design different components of whole platforms. Thus, they need to collaborate and keep in touch with suppliers often.
Real-World Requirements
Aerospace and military engineers are normally under pressure to choose the right components for particular tasks. For example, interconnects and cables used in defense cars need to have a long life span as they work in adverse conditions like extreme temperatures, salty water, and constant vibration. Besides, they need to withstand tear and wear due to continuous unplugging and plugging.
Ruggedization is a major difference between cables and interconnects made for commercial use and those designed for aerospace and military applications. Unmanned systems and new military aircraft have many applications. Thus, engineers need to shield them from pulse (EMP) and electromagnetic interference (EMI). Many modern military aircraft send multispectral and high-resolution imagery.
Standards-Based Selection
Aerospace and military engineers use consistent, reliable, and robust standards-based products. Dabrowski from Ampenol states that electrical assembly engineers are gradually shifting from using vendor proprietary products to standards-based solutions. For example, the Defense Logistics Agency (DLA) has shifted from SAE International to SAE Aerospace Standards (AS). NAVSEA S9320-AM-PRO-020/MLDG-certified over-molding is one of the requirements of custom cable assemblies.
Several industry standards which started as military specifications have transformed into SAE standards. Most large Original Equipment Manufacturers (OEMs) have AS specifications for wires and cables. Clients value different compliances and cable assembly certifications like IPC 620, MPD-7011, MIS-20887, and IPC J-STD-001E. Some of them need AS9100-quality systems.
Signal Integrity
Signal integrity is important when selecting aerospace and military cables and connectors. Connectors receive and pass pure signals. Engineers need to design and manage signal integrity as voltages reduce and speed increase. Also, it is necessary to pick the right connector to match a design.
