Mouser - White Papers

Mouser Electronics White Paper The aerospace and defense (A&D) industry delivers platforms and equipment for some of the most demanding conditions on Earth and beyond. Mission-critical applications in such conditions create a significant engineering challenge. Electronics systems operating in extreme environments require connectors that deliver rugged and reliable performance. However, the nature of A&D systems is changing. While environmental conditions remain challenging, operators are adopting new technologies to adapt to them. New methods of powering and moving vehicles are gaining popularity, and the A&D marketplace is seeing the growth of electrification in parallel with commercial and consumer vehicles. High-performance and edge computing are becoming essential tools for the modern soldier. Tactical computing, a defense adaptation of edge computing specifically designed for contested and resource- constrained environments, takes this one step further. From ground vehicles and tactical aircraft to satellites operating in the vacuum of space, designers are integrating increasingly complex electronics into the latest A&D platforms (Figure 1). These systems must operate in unforgiving conditions, often autonomously, providing sensing, computing, and coordination capabilities. Figure 1: Intricate control systems in A&D applications are placing new demands on the electronics that power and move aircraft. (Source: Andrea Izzotti/stock.adobe.com) Central to these capabilities are the connections that link critical systems, delivering power, data, and signals where they are needed most. Connectors are among the few components directly exposed to the environment, making their ruggedness and reliability essential. When designing for A&D applications, engineers must select components that not only meet stringent standards but also prove dependable over their full operational lifespan. An example of the critical nature of connectors can be found in the data networks of fourth-generation aircraft such as the F-16. Unlike previous aircraft, the pilot's controls are not physically connected to the control surfaces. Instead, the flight-control computer receives inputs from the pilot and converts them into electrical signals, which then activate the control surfaces. This use of computers to direct flight enabled the concept of relaxed stability, in which the aircraft is deliberately unstable. This makes the aircraft highly responsive and capable of rapid maneuvers, but renders manual control impossible. The flight-control computer relies on sensors to detect changes in motion, attitude, and acceleration. Connectors must reliably carry these sensor and control signals, despite the dynamic environments found in modern tactical aircraft. Even under shock, vibration, and extreme temperatures, control signals must reach the flight-control computer to ensure the safety of the aircraft and crew. Compliance with standards provides engineers with confidence that their systems will perform under pressure. This article explores what "rugged" and "reliable" mean for A&D, examines how connector design addresses these challenges, and explains how Molex acquiring the AirBorn connector portfolio enhances its solutions for mission-critical A&D applications. Defining Ruggedness and Reliability Ruggedness and reliability are closely related terms for engineers. In industrial applications, they might even be used as synonyms, but in the A&D world, they have very specific meanings. These definitions are the result of decades of development and real-world experience. Applying these terms to connectors allows designers to clearly understand how they will perform in tough conditions. Ruggedness Rugged connectors are designed to function consistently, even under extreme conditions. A rugged connector must withstand clearly defined conditions: • Shock and vibration: This includes exposure to sudden forces and long-term mechanical vibration, which are commonly found in armored vehicles, tactical aircraft, and missile applications. • Temperature extremes: Defense equipment is expected to perform flawlessly, from the icy cold of the Arctic to the heat of the tropics. The operation of the equipment itself can cause temperature swings, requiring careful calculation of ambient temperatures. • Sealing and ingress protection: As connectors are often mounted to the external parts of A&D equipment, they must resist the dirt, moisture, and other contaminants that could damage both the connector and the electronics within.

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