Overmolded Interconnect Cable Assemblies for Aerospace Applications
description
Transcript of Overmolded Interconnect Cable Assemblies for Aerospace Applications
Overmolded Interconnect Cable Assemblies for Aerospace Applications
Flawless Performance: Over 50,000 Glenair Overmolded Cable Assemblies Have Been Installed in F-16s without a Single Failure
High Performance Cable Assemblies Must Be Able to Withstand Damage From:
Shock Vibration Fluid Immersion Abrasion Clamping Combustion Corrosion
Temperature Cycling in Jet Fuel Altitude Fungus Pressure Extremes Pull Forces Outgassing Aging
Environmental/Mechanical Stress Factors in Aerospace Interconnect Cables
Viton, EPDM, Butyl and Glenair proprietary materials provide robust protection for connectors and cables in harsh/caustic environments
Mechanical performance is also enhanced Injection molding/transfer molding is a
simple, reasonably priced solution to physical protection
Design flexibility: from simple point to point, to complex multiple branch assemblies—even fiber-optic and hybrid electrical/optical designs
Outstanding environmental protection for harsh and caustic environments compared to braided or booted solutions
The Advantages of Overmolding
Typical Cable Construction
Connector Overmold Cross-Section
Overmolding effectively eliminates all cable and wire ignition sources, including arcing and ESD
Also improves longevity of service
Reduced installation and maintenance cost
Controls corrosion/conductivity problems
Improves reliability and safety
Turnkey Solution to FAA SFAR-88 Requirements
Overmolding as a Solution to Managing Single-Point Ignition Sources in Aircraft Fuel
Cells
Turnkey solutions with Glenair Connectors, Backshells, and Assembly may be optimized for reduced weight
Routing performance enhanced with range of standard Glenair tooling for all angles and junctions
Efficiently Designed Multi-Branch Harnesses Reduce Overall Weight and Package Space of Interconnect Cables
Overmolding as Solution to Cable Routing and/or Weight Reduction
F-16 Fighting Falcon Modular conduit designs failed
repeatedly in F-16 and other front-line fighters.
Glenair introduced unique design to solve leakage, reliability and installation requirements
Design incorporated new overmolding materials and integral bulkhead fittings
History of Glenair Overmolded Cables for Fuel-Cell Applications
Proven Performance for Bell, Lockheed, Boeing and ETC
F-18 Fuel-Cell Assembly Advanced F-18 E/F Fuel Cell
Assembly with integral fiber optic media
F-22 Overmolded Fuel Cell Assembly and Wheel Well Assemblies
V-22 Fuel Cell Assembly Bombardier Bulkhead Fuel-Tank
Connector Assembly C-17 Overmolded Conduit Fuel Cell
Assembly
Additional Military Reference Applications
New Glenair Design Met all Requirements and Significantly Reduced Installation and Maintenance Costs
Sealed conduit system with integral clamp mountings
Replaced rigid metal tubing system with significant installation cost savings
Achieved all safety, reliability, and weight objectives
Spotlight On Glenair’s C-17 Overmolded Conduit Solution
New Glenair Design Met all Requirements and Significantly Reduced Installation and Maintenance Costs
C-17 Overmolded Conduit Solution: Detailed View
Straight, 90 and 45 degree angular specifications.
Existing tooling for all common molding adapters and connectors.
Breakout, bulkhead and transition tooling for all common configurations
Standard molding materials as well as new proprietary formulas and new mass-produced injection processes.
Molded Cable and Connector Identifiers
An almost unlimited range of breakouts and layouts
Cable Routing and Packaging
Capabilities
Overmolding as a standard catalog offering
Point-to-Point cordsets available for all Series 80, Series 22 and D38999 fiber optic connectors
Standardized part number development
Accelerated lead times
Production Packaging
For exacting operational and environmental conditions
Custom electrical, fiber optic and hybrid configurations Bulk cable supplied in short one-time runs as well as
unlimited quantities and lengths One of the industry’s broadest selection of braided
shielding, coverings and extruded jacketing, including NBC (nuclear, biological, chemical) materials
Cable design and engineering support covering every EMI/EMP, mechanical and environmental design consideration
Additional Cable Shop Capabilities: Custom Multi-
Conductor Cables
Durable lightweight cable assemblies
Flexible, and elastic overbraiding provides physical protection and EMI Shielding
Extreme temperature protection: from -100oF to +500oF
Smoothes irregular shapes and reduces snagging in lacing- tape bound harnesses
Adds flexibility and repairability to harness designs
Available in bulk or integrated into the harness assembly service
Additional Cable Shop Capabilities: Metal and Fabric
Overbraiding
Nickel Plated Composite Shielding Offers Unique Solution to Electromagnetic Compatibility
Expandable, flexible, high-strength, conductive, elastic composite material
Provides abrasion resistance and EMI shielding at a fraction of the weight of metal braid
Ultra-Lightweight Composite RFI/EMI Braided Shielding
The Bid Process
Assessment of overmolding work is essentially a bid process and costing exercise as most jobs are submitted with complete BOMS and assembly schematics.
New applications are nevertheless evaluated for mechanical, EMI and environmental requirements.
Glenair will often add value with superior knowledge of wire and cable layout and assembly, especially in prototypes.
Application Development
The Ultimate Harsh Application Environment
Halliburton’s Oil Well Recovery and Restoration Division employs specialized trucks equipped with seismic recorders to generate accurate oil well status data. The field generators which power the system use interconnect cabling which must withstand severe weather, abusive handling and caustic chemicals. Glenair overmolded cable assemblies provide flawless, durable service in this extreme environmental application
Not Just Another Pretty Cable