Optimized hybrid solutions for defense applications - Connectors

The pressure to develop technical designs that are not only reliable but also user-friendly and simple is a must. Military equipment and its operators experience extreme stress situations and must be as well-prepared as possible. But what options do engineers have to enable user-friendly operation while RoHS guidelines, environmental requirements, and desired functionality shape the design?

Requirements for the connection of electronic devices

Electronic devices need a power supply, and data integrity from sensors and optical systems is crucial. Most devices, whether worn by soldiers or installed in ground combat stations or vehicles, have wired transmission because it is less susceptible to manipulation. Portable systems can be powered via an integrated battery, but connecting an external battery offers many advantages:

• Extended lifespan due to increased battery capacity
• Better ergonomics through adjustable weight distribution
• Easy battery replacement

Imaging in military optronics is based on data from infrared, UV, or X-ray sensors alongside conventional video recordings. As an alternative to fiber optic technology, coaxial cables particularly offer the necessary requirements and, in addition to high bandwidth capacity, provide good shielding against external electromagnetic interference. Compared to fiber optic contacts, they have significantly lower maintenance costs.

Advantages of hybrid interfaces

The combination of power and data transmission in a hybrid cable requires connectors and cables that are adapted to the requirements and still offer high performance. Integration ensures a more compact installation space and can lead to overall cost savings. The benefits for the operator are:

• Increased mobility and convenience due to a reduced number of cables and interfaces.
• Increased reliability, as fewer interfaces reduce the risk of cable breakage and connection errors due to damage.
• Faster operational readiness thanks to less effort in putting on and taking off equipment.
• Easier maintenance and repair. A reduced number of potential error sources simplifies troubleshooting and repair. This lowers maintenance costs and increases the lifespan of the equipment.
• Improved safety as a reduced number of cables decreases the risk of soldiers getting entangled in their equipment or environment.

The integration of hybrid cables in portable systems is possible, for example, using a hybrid connector such as the ODU AMC® High-Density (HD). The connection solution, specially optimized for military applications, enables the combination of power and data transmission with an outer diameter of only 12.8 mm.

The combination with polyurethane (PUR) sheathed hybrid cables is a good way to make optimal use of the potential of the connector. The thermoplastic elastomer (TPE) is characterized by its high tear, notch, and abrasion resistance, as well as its particular resistance to liquids such as oils, gasoline, and solvents. The German manufacturer has a wide range of standard products and supplies complete, tested ready-to-use assemblies.

Solutions for larger systems

The optronic systems are often permanently installed in vehicles, command posts, or mobile surveillance units. The interaction of various sensors provides a detailed overall picture of the environment. The required power and large amounts of data can usually not be transmitted via miniaturized connection solutions such as the AMC HD. The AMC portfolio of the manufacturer ODU also offers specifically developed solutions for these requirements.

Connections with 50-ohm coaxial contacts are available in both the High-Density and the ODU AMC® Classic series. For the safe transmission of uncompressed HD video signals, 75 Ohm coaxial contacts in the classic AMC connector are ideal.

Conclusion

The use of highly advanced optronics places special demands on device manufacturers. The power supply and connection of military equipment to existing systems can be solved by specialized connections, using various sizes and technologies. Hybrid solutions such as the ODU AMC® HD connector with matching PUR cables offer significant added value for integrators and end-users by reducing the number of interfaces.