Omnetics Connector Corporation, a veteran in military-grade interconnection systems with over 35 years of experience, provides crucial components for defense equipment deployed everywhere from Mars rovers to battlefield communications.
The Modern Battlefield: A Web of Connected Technologies
Today’s defense systems rely on an intricate network of technologies that maintain constant communication across various elements of the battlefield. From satellite data centers to individual soldier equipment, these systems demand reliable, high-performance interconnects that can withstand extreme conditions.
Omnetics specializes in developing connectors and cables that meet these challenges head-on. Their products are integral to military systems such as satellite communication systems, autonomous drones and weapons, soldier-worn modules and helmet-mounted devices, and LIDAR-based surveillance equipment.
Meeting the Challenges of Miniaturization and Ruggedization
As defense equipment becomes more compact and mobile, it faces increased physical stresses. Omnetics’ Micro and Nano connectors are designed to endure the constant vibration during ground travel as well as shock, for example in drone landings, and high acceleration, such as in missile systems.
These connectors, built to military specifications such as MIL-DTL-32139, utilize advanced materials like beryllium copper pins with nickel and gold plating to ensure durability and reliability in harsh environments.
Evolution of Circular Connectors for Defense Applications
The defense industry’s relentless pursuit of miniaturization has led to significant advancements in circular connector design, with a focus on reducing size while simultaneously increasing signal speed for field use. This evolution is particularly evident in the development of new standards that are reshaping the landscape of military interconnect systems.
Traditionally, the MIL-DTL-38999 circular connector has been a staple in defense applications, utilizing 18-20 size pins capable of carrying up to 12 Amps on 20 AWG wiring. However, the industry is now moving towards miniature military 38999 connectors, which are being standardized by multiple companies to provide smaller, more universally available options.
Omnetics Micro Circular Hybrid Connectors
The advanced design of Omnetics’ Micro Circular connectors feature a triple-start thread coupling system, enabling quick mating even when wearing gloves and ensures robust EMI shielding, addressing the critical need for signal integrity in complex defense systems.
The new standard offers size 23 pins and smaller, handling a wide range of amperages from approximately 10 Amps down to 3 Amps, and is compatible with 24 to 30 AWG wire. For applications demanding the utmost in compactness, Omnetics provides circular connectors with size 30 pins, supporting 1 Amp and compatible with 30-32 AWG wiring.
The impact of this miniaturization is substantial. Pin-to-pin spacing has been reduced from over 75 mils to a mere 25 mils, resulting in significantly smaller connector and cable diameters. This reduction not only decreases the overall size and weight of defense systems but also improves cable flexibility.
Customization for Specific Defense Applications
These advancements in circular connector design are enabling the creation of more compact, lighter, and more flexible defense systems without compromising on performance or reliability. Recognizing that one size doesn’t fit all, Omnetics also offers customized solutions such as:
- Hybrid connector systems combining power and data transmission
- Miniaturized versions of standard military connectors like the MIL-DTL-38999
- Micro Circular connectors with triple-start thread coupling for quick, gloved operation and EMI shielding
The Path to Rapid Prototyping
Omnetics employs cutting-edge design processes to accelerate product development. These include:
- Collaborative solid model design with defense manufacturers
- Rapid prototyping using 3D modeling and fabrication
- Customization based on specific electrical, environmental, and physical requirements
As defense technology continues to advance, Omnetics remains committed to providing interconnect solutions that meet the industry’s evolving needs. Their focus on miniaturization, ruggedization, and customization ensures that military equipment can perform reliably in the most demanding conditions.
Find out more on about military-grade interconnect solutions for on-board mobile electronics on the Omnetics website.
