Why Are Special Cable Assemblies Required In Military Applications?

Military cable assemblies have the same basic requirements as cable assemblies for other industries, that is, carrying power and information from one place to another. But, there is yet a great difference between general cable assemblies and military cable assemblies as the latter is required to perform in much harsher environments, and must in no condition fail. This is why it is critical that these cable assemblies are subject to exacting standards set by the military applications, and that they are able to withstand constant use in variable climates and harsh conditions. This is why military specific cable assemblies are designed to provide reliable performance and durability in demanding applications. Miracle Aerospace is one of the most reliable military and aircraft cableassembly manufacturers in India, where all standards are kept in mind while designing cable assemblies. Moreover, the products manufactured specifically for military purposes are designed to have the following qualities, such that they can fulfill the needs of the below mentioned applications.

Qualities required by military cable assemblies

Flexibility – Military cable assemblies must be sturdy enough to withstand frequent stretching, twisting, and contracting of heavy use. A coiled cord or stranded cords may be used in individual wires to enhance the assembly’s flexibility, depending upon the requirements of the application.

Durability – Military cable assemblies are always encountering varied climates and temperatures. This is why they must be designed to address the most challenging conditions by usage of tools that create strain reliefs and overmoulded connectors, which can withstand harsh environments.

Resistance – Military cable assemblies come across all kinds of vibrations and abrasions. Thus, they must be jacketed with advanced polyurethane jacketing for superior resistance against all kinds of abrasion, moisture, chemicals, and bio-contaminants.

Protection – Military cable assemblies must be shielded to provide EMI/RFI performance that meets military specifications. These can include braids, tape shields, composite shields, spirals, and reverse spirals.

Applications military cable assemblies are used in

Aviation – Cable assemblies used in military aviation applications are constructed out of lightweight materials like carbon fibers, which can comprise a simple thin design. These assemblies also need to be designed to withstand high temperatures and pressures.

Defense vehicles – Military cars, jeeps, and trucks endure immense stress on the field. This is why lightweight connectors that are small in size are used, which increases the application space, without adding to the weight of the vehicle. The cables also need to be waterproof to ensure that the vehicles do not stop functioning during rains, or when passing through damp and water-filled areas.

Soldier worn systems – Soldiers are made to wear multiple systems on the field that use cable assemblies. Cables with superior elasticity are used so that cables can be stretched when worn outside military gear, or within the protective armor and clothing. Also, RFI shielded assemblies are required to keep the devices protected against sand, dirt, chemicals, and water.

Communication – Communication within the military industry needs to be perfect and fault-free. It requires immense amount of protection as they are used in a wide number of settings. This is why materials like tinned copper, carbon fiber, Teflon, beryllium copper, HDPE, and PVC are used; and connectors are designed using overmoulding processes for improved protection.