Connecting the Future of Flight

­Aircraft are intricate systems comprised of numerous interconnected computers that continuously communicate with each other. These onboard electronic systems are organised into hierarchical networks, facilitating interaction among various devices. Despite their small size, connectors play a important role in bridging connections between various components and ensuring the seamless operation and safety of modern aircraft. Here, Alex Raymond, European product manager at connector specialist PEI-Genesis, delves into their significance, exploring key functions and challenges for aviation systems.

The aerospace industry today depends on mission-critical electrical and electronic systems to maintain safe operations. These systems include navigation, communication, engine control, and flight control functionalities. Navigation systems guide pilots from one location to another, while communication systems allow them to stay in touch with air traffic controllers and other aircraft. Engine control systems oversee and adjust engine performance, and flight control systems ensure the aircraft remains stable and follows its intended path.

Powering these systems is a network of cables and connectors. Aircraft electrical connectors are specifically designed to withstand the extreme conditions, such as high temperatures, low temperatures, intense vibrations, as well as high altitudes - alongside fuel and hydraulic fluid contamination.

Key functions of connectors in aircraft systems

Connectors are vital for transmitting signals between different systems onboard the aircraft. These signals include data and commands that control everything from the aircraft’s flight control systems to its communication and navigation equipment. The accuracy and reliability of these signals are paramount to ensure proper functioning and safety.

As modern aircraft rely heavily on sophisticated data networks for operations and diagnostics, connectors are designed to enable the high-speed transfer of data between various sensors, processors and control units. This data transfer supports real-time monitoring and control of aircraft systems, improving performance and safety.

Similarly, connectors are designed to protect electrical connections from harsh environmental conditions commonly found in aviation, such as extreme temperatures, humidity, vibration and electromagnetic interference. They ensure that connections remain stable and corrosion-free, maintaining the integrity of the systems.

Challenges in the world of aircraft connectors

Despite their importance, connectors face significant challenges. One of the primary issues is the need for miniaturisation without compromising performance. As aircraft designs evolve to become more compact and efficient, the components, including connectors, must follow suit. This requires innovative engineering to ensure that smaller connectors can handle the same, if not greater, loads and stresses as their larger predecessors.

One of the biggest challenges of miniaturising connectors is ensuring they maintain high electrical performance. Smaller connectors must still handle the same electrical loads, which can range from a few milliamps for signal connectors to several amps for power connectors, typically up to 5A per contact, and voltage levels up to 300V RMS, and signal integrity requirements as their larger counterparts. This includes managing high current flows, minimising resistance, and preventing signal loss or degradation over long distances.

Smaller connectors can also face difficulties with heat dissipation. As electrical components become more compact, the density of electrical currents can lead to increased heat generation. Efficiently dissipating this heat is crucial to prevent overheating and ensure the longevity and reliability of the connectors. Advanced materials and innovative design techniques are often required to manage thermal performance in miniaturised connectors.

Connectors must also be able to integrate with emerging technologies such as high-speed data transmission, fibre optics and wireless communication. Ensuring that miniaturised connectors can support these technologies while maintaining compatibility with existing systems adds another layer of complexity to the miniaturisation process.

To address these evolving demands, Amphenol’s new Raptor Series connectors offered by PEI-Genesis have been engineered specifically for high-power systems in e-flight, e-VTOL, and hybrid applications. Designed for high voltage and high current environments, they feature TALON high-temperature contacts and silver-plated copper contacts housed in nickel-plated aluminium shells.

These connectors are tailored to withstand the increased operating voltages at aircraft altitudes, thanks to their advanced insulation geometry, which enhances protection against high-voltage electric fields and boosts safety. With shell sizes ranging from 15 to 25, the Raptor Series connectors are a perfect fit for aerospace applications that demand reliability and robustness in the most extreme conditions.

In the complex and highly demanding world of aircraft systems integration, connectors stand out as crucial components that ensure the seamless operation and safety of modern aviation. They perform essential functions such as power distribution, signal transmission, data transfer, and environmental protection. As we continue to push the boundaries of aviation technology, connectors will remain indispensable, their role ever more critical in supporting the advancements that define the future of flight.