How Modulus™ is Revolutionizing Cable Harnesses for Aerospace
Working with aerospace, satellite, and unmanned aerial systems (UAS) platforms often means grappling with gravity, tight spaces, and environments with extreme temperatures. In the past, when new requirements were added to platforms the cable harness solution almost always became heavier, larger, and significantly more complex. Well, those days are over.
With pressure from competing departments to shrink system footprint while maintaining the high-power and high-density data transfer of today’s cutting-edge avionics, sensors, and data communication buses engineers need interconnect components that do more than simply connect two points. Modern harnesses require platforms that are rugged, lightweight, flexible, and configurable.
Today’s cable assemblies start with Modulus™, Aptiv’s newest ruggedized modular connector platform. But what exactly is Modulus, and how is it improving cable harnesses for aerospace engineers? Let’s dive in.
The Shift from Complex to Configurable
Adding new sensors to a payload or changing requirements often means reconfiguring your wiring harness and accommodating new connectors. When you’ve got hundreds of wires controlling your primary functions, that Frankensteined solution just doesn’t cut it. Modifying pin configurations, breaking out additional power circuits, or relocating connectors means more expense and delay.
Modulus™ solves these problems by offering a complete, fully configurable solution. Engineers can configure individual modules within a connector for power, signal, or high-speed data transmission eliminating the need for redundant connectors across similar drone or satellite models. When requirements change or upgrades are needed teams can simply exchange modular plugs instead of thinking through a full harness redesign.
4 Key Ways Modulus™ Improves Aerospace Harnesses
- Lightweight Design: Size, weight and power (SWaP) is king. Modulus™ connectors feature lightweight materials and a small form-factor specially designed for space-constrained UAS applications. Combining your power connections with high-speed data reduces total cable count and opens up more room in your airframe for that next sensor.
- Built-in High Speed Capability: If your next drone or satellite needs to transmit gigabytes of data, Modulus™ has you covered. The modular plug includes SPE function with multi-megabit performance up to 10Gbps for seamless power, signal, and data integration all in the same connector. Maintaining controlled impedance in high-speed modular connections is a challenge. However, Modulus™ accomplishes this with optimized contact design allowing engineers to reduce harness complexity without sacrificing bandwidth.
- Streamlined Field-Serviceability: Satellites aren’t exactly convenient to reach when you’re in the shop diagnosing a faulty sensor. The interchangeability of Modulus™ allows for quick-serviceability in the field by replacing only the modules that are damaged or need to be reconfigured without removing the entire plug or harness.
- Built Tough: If it’s going to space, it has to withstand space conditions. Modulus™ connectors are built with durable thermoplastic material options and are rigorously tested to ensure they can withstand shock, vibration, and harsh temperature variations. Manufacturers can trust Modulus™ to maintain secure connections and consistent performance season after season.
Designing for Tomorrow, Today
There are many ways to improve your cable harness, but reducing wire gauge won’t matter if you aren’t also improving your termination solutions. Modulus™ gives engineers a standardized platform for designing modules that need to be serviced in the field. With the ability to create custom configurations, engineers can future-proof today’s densest platforms without expanding the overall complexity of the cable assembly.
Connectors are the foundation of any aerospace or defense system. If you find yourself limited by current interconnect solutions or are forced to choose between functions because of product constraints, it may be time to consider a modular platform. Aptiv is dedicated to designing revolutionary products that expand possibilities for our customers.
To learn more about how Modulus™ can simplify harness design, reduce system weight, and maintain operational readiness, contact our engineering team today.