Cinch Connectivity Solutions is aware that the meteoric rise of unmanned aerial vehicles (UAVs) and unmanned underwater vehicles (UUVs) in military operations has sparked significant advancements in supporting technologies. Read more >>
Despite this fast-paced development, many in the defense sector remain unaware of the most effective connectivity solutions available for these unmanned systems. As military drones grow more compact, feature-rich, and robust, their connectivity requirements are becoming increasingly demanding.
Accelerating Technological Innovation in UAVs & UUVs for Defense
Military drones have seen significant adoption due to their ability to perform reconnaissance, surveillance, and tactical missions efficiently.
By 2025, military UAVs are expected to dominate 70% of global drone sales, projected to reach $14 billion annually. This surge in demand is driving the need for more advanced, lightweight, and high-performance unmanned systems.
Military UAVs and UUVs must be portable, versatile, and capable of enduring extreme operational environments. This means they must function in temperatures ranging from -55°C to +200°C, withstand high shock and vibration, and resist wear from frequent handling and transport.
In addition to these environmental challenges, UAVs often operate at high altitudes, where they are subjected to continuous use, further emphasizing the importance of robust designs.
Critical Connector Requirements for Military UAVs
The complexity of military UAVs lies in their growing need for advanced features. Modern UAVs are equipped with satellite-based GPS, thermal and night-vision cameras, multiple sensors, wireless communication systems, and digital radios. They are also required to store and stream vast amounts of video data and, in some cases, carry intelligent weapon systems that can be remotely deployed.
To support these capabilities, UAVs must rely on highly reliable, interference-resistant connectivity solutions that maintain signal integrity and withstand long-distance travel. Connectors play a crucial role in this, as they ensure the smooth transmission of data and power across the system. These connectors must not only be rugged and lightweight but also capable of operating seamlessly with other components within the UAV.
Military UAV connectors, particularly microminiature D-Type connectors with solder or crimp contacts, must meet the stringent MIL-DTL-83513 specification. This standard, set by the U.S. Defense Logistics Agency (DLA), governs the use of connectors in harsh environments where standard D-sub connectors are too large or heavy.
To further reduce the size and weight of UAVs, the industry is exploring the use of nano-miniature connectors, which offer low contact resistance, high current capacity, and enhanced dielectric strength without compromising on durability.
Key Considerations for Developing UAV Connectors
Circular connectors have emerged as a preferred solution for military UAVs due to their space-saving design. The best drone connectors often feature brass shells that protect against electromagnetic interference (EMI) and radio frequency interference (RFI), along with ingress protection rated to IP67.
These connectors must also be flame-retardant and securely fastened to prevent disconnection due to vibration during flight or mission-critical operations.
Other environmental challenges for connectors include exposure to high humidity, corrosion from chemicals, and pressures of up to 20,000 PSI in UUV applications. Ensuring that connectors are resistant to dirt and dust, and preventing issues like mis-mating or accidental disconnection, are also top priorities when designing connectivity solutions for military UAVs.
Engineers must carefully evaluate voltage requirements, wire gauge, crimping or soldering options, and the need for additional accessories such as backshells and ID solutions.
Depending on the application, connectors may need to support cable-to-panel or cable-to-cable installation. Customization options for finishes and contact arrangements are essential for achieving optimal performance in varying environmental conditions.
Cinch Connectivity Solutions: Leading the Charge in Military UAV Connectivity
Cinch Connectivity Solutions, part of Bel Group, is at the forefront of providing high-performance connectors for military UAVs and UUVs. Their ruggedized solutions are designed to withstand the most challenging environments, ensuring seamless integration with other systems used within drones.
One notable offering is the Cinch Mil/Aero Circulars MD801 Series connector. Available in both standard and specialty plated finishes, this connector is built for extreme environments and can support crimp, solder, or PC tail terminations with between 1 and 130 contacts.
Its shell styles include jam nut receptacle, square flange receptacle, and in-line plugs, offering versatile configuration options to meet the diverse needs of military drone developers.
Cinch also offers the Dura-Con Micro-D connectors, which are high-performance, compact units with a 1.27mm (0.05”) pitch interconnect. These connectors are ideal for applications where space is limited but reliability is paramount.
For instance, the Dura-Con Micro-D hermetic connector is sealed to a leak rate of less than 1 x 10-8 cc He/sec and built to withstand shock and vibration in line with MIL-STD-1344 standards. With a current rating of 3A and an operating temperature range from -55°C to 125°C, these connectors are designed for maximum durability in demanding military environments.
Cinch’s nano miniature circular connectors, which offer hermetic sealing, are ideal for critical applications where preventing leakage is a priority. These connectors can endure extreme changes in temperature, pressure, and humidity, making them suitable for both UAV and UUV systems. Customizable options include in-line, panel, or box-mount receptacles with composite, stainless steel, or aluminum shells.
Meeting Future Demands: Micro and Nano UAV Connectivity
As the military drone market continues to evolve, the future will see a growing emphasis on micro and nano UAVs. These smaller platforms will require even more advanced connectivity solutions that optimize size, weight, and power (SWaP) without sacrificing performance.
Military drones of the future will need to fly farther, carry more features, transmit larger volumes of data, and ensure mission reliability, all while operating in increasingly harsh conditions.
To meet these demands, connectors and cables will need to become lighter, more compact, and more robust. The challenge is clear, but the tools to overcome it are already in development, ensuring that the military drone sector is well-equipped for the future.
The continued advancement of military UAVs and UUVs depends on the development of robust, high-performance connectivity solutions that can withstand extreme environments while maintaining optimal SWaP ratios.
As a leader in this field, Cinch Connectivity Solutions provides a range of specialized connectors that ensure reliable performance in mission-critical military applications. With the future of military drones hinging on miniaturization and enhanced functionality, the role of advanced connector technology will be more critical than ever in enabling successful operations.
Read the original article, or visit the Powell Electronics website for more information.
