Ultra Light Weight Interconnect System
Application
Ultra light weight interconnect system applying 'Cat of 6 Tails' principles from a micro connector to a small bank of sensors.
Key Features
Both weight and space were required to be kept to a minimum. Reliability was all important in this Aerospace/Defence type application.
Timescales
A rigid timescale of 4 weeks involved tooling and specialised grounding ferrules.
Scenario
Weight reduction was achieved using micro miniature twisted pair wires with a stainless steel braid for EMI/RFI purposes. No additional conventional cable jacket was used which simplified the sensor termination in the restrictive space available. To ensure effective grounding for the sensor a gold plated ferrule was used to create a bolt on reliable stud style fixing.
 Light Weight Interconnect System |
Actual
A customised back shell was tooled up to suit both 3 & 5 way variants of the sensor connector. It was necessary to encapsulate all backshells to withstand +150 to -150 degrees C. Specialised wire was sourced, screened and in turn made into a special braided (no jacket required) cable.
Summary
4 sets of low weight, hig reliability, microconnect cables were manufactured, tested, and subsequently flown within projected timescales.