Aerospace Equipment Connection Harnesses and Cables

Aerospace equipment connection cables, often called cable assemblies, are crucial for transmitting electrical signals, Leistung, and mechanical motion within aircraft and spacecraft. They are designed to withstand extreme environmental conditions and are used in various systems, including flight controls, engine controls, and navigation systems.

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The design and manufacturing of aerospace equipment connection harnesses and cables integrate high reliability, lightweight and intelligent technologies. Its core features are as follows:
I. Technical Features
‌Materials and Performance‌
High-performance insulating materials such as polytetrafluoroethylene (PTFE) and polyimide composite materials are used to ensure that the cables can work stably in extreme temperatures ranging from -65°C to 260°C, and have corrosion resistance and flame retardancy.
The composite cable structure design (such as wrapped cables and extruded cables) improves signal transmission stability, reduces losses, and meets the high-frequency signal transmission requirements of aerospace.

‌Intelligence and Customization‌
Introducing the concept of intelligent manufacturing, real-time monitoring of the production process through automated equipment (such as winding machines, cabling machines) and digital management systems to ensure process accuracy and efficiency1.
Supports on-demand customization, covering different wire gauges (such as 18AWG), voltage levels (such as 1000V) and length specifications, and adapts to the differentiated needs of satellites, rockets and other equipment.

Reliability:
Aerospace cables are engineered for dependability and long-term performance, even in challenging environments.

Robustness:
They are designed to be durable and resistant to shock, vibration, abrasion, and other factors.

Weight Reduction:
Aerospace cables often prioritize weight savings to improve fuel efficiency and payload capacity.
Flexibility:
They are designed to be flexible and easily routed, even in tight spaces.

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Specific Uses:
Flight Control Systems: Connecting sensors, Aktuatoren, and displays for precise control.
Engine and Landing Gear Control: Facilitating power distribution and control in critical systems.
Electrical Systems: Connecting power sources (engines, generators, Batterien), as well as various electrical equipment (lights, entertainment).
Safety Systems: Supporting brakes, seatbelts, airbags, and fire detection systems.

Types of Aerospace Cables:
Aircraft Control Cables: Specifically designed to transmit mechanical motion from the cockpit to control surfaces.
Electrical Cables: Used for transmitting power and data.
Specialty Cables: Like M16878, known for their resistance to extreme temperatures, chemicals, and fuels.
PICMates Cables: Engineered for long-term performance in demanding aerospace conditions.
Cable Assemblies and Connectors:
Cable Assemblies: Multiple conductors bundled together with a protective coating.
Anschlüsse: Securely connect cables to other components, ensuring reliable electrical connections.
Popular Connector Types: M24308, ARINC 600, USB Type-C.
Importance in Aerospace:
Aerospace cables are vital for the safe and reliable operation of aircraft and spacecraft. Their performance directly impacts safety, performance, and the overall efficiency of these complex systems.

II. Manufacturing process and quality control
‌Production process‌
The automated production line realizes seamless connection of wire drawing, twisting, extrusion and other processes, and is combined with a variable-caliber wire harness fixture device to flexibly adapt to the clamping and angle adjustment of wire harnesses of different sizes.
Energy-saving equipment and wastewater treatment technology are used to reduce energy consumption, and the production process meets environmental protection standards1.
‌Quality inspection‌
Through multiple testing methods such as continuity test, leakage voltage test and visual inspection, ensure that the electrical performance and mechanical strength of the wire harness meet the standards.
Some companies are equipped with a full-process traceability system to achieve quality traceability from raw materials to finished products.

III. Product standards and certification
It is necessary to pass ISO 9001, IATF 16949 and other quality management system certifications. Some military-grade products also need to have equipment manufacturing qualifications, secondary confidentiality qualifications and weapons research and production licenses.
International leading companies (such as Nexans) have also obtained certifications from aviation manufacturers such as Airbus and Boeing, and their products cover both civil and military fields.

IV. Typical application scenarios
Aircraft internal power supply system: FLVL aviation wire/high and low temperature resistance/lightweight/salt spray corrosion resistance;
Satellite signal transmission: low-loss coaxial cable/high frequency stability/low signal attenuation;
Engine electrical connection: fire-resistant cable/high temperature resistance/radiation resistance;
Cabin equipment wiring: customized electronic wiring harness/high-density wiring/anti-electromagnetic interference;
The aerospace cable industry is promoting technological iteration through intelligent manufacturing and material innovation, and will further develop in the direction of integration, lightweight and enhanced environmental adaptability in the future.