Aerospace, Military & Defence Focus
Beyond these, mixed-functionality options enable the combination of signal, power, and coax on a single unit.
According to Ben, connector selection in development will frequently be iterative, evolving as part of ongoing system optimisation. During the design process, engineers might make trade-offs between size and durability, cost and reliability, or mechanical robustness and packaging constraints. But if, for instance, an application subsequently needs higher power input, or the mechanical stress under vibration in use increases, the ability to transition between families with as few design implications as possible becomes important — for example, to increase current rating or to implement a secure six-fi nger contact mechanism. And features such as pre-crimped and pre-potted cable assemblies can also be used to reduce production complexity and allow faster assembly, improving manufacturing turnaround times.
Testing and validation
With visionair specializing in fail-safe power management systems, testing is a vital part of its development process. Propulsion packages and other sub-systems are evaluated in its
Figure 2: visionair has adopted Harwin’s hi-reliability HRi range of connectors, including Datamate, Gecko, and Kona to address the core reliability challenges of UAV avionics.
in-house-developed test cell, designed to push components and systems to their limits to test endurance, effi ciency, wear and tear, functionality, and system specifi cations and limitations. The focus is on real-world system behaviour, rather than isolated component testing. Validation is conducted on fully assembled systems, which are then exposed to real-world operating conditions, including high current loads, as well as high vibration and a wide range of thermal conditions. Insights during this process can sometimes infl uence connector choice, as part of ongoing system optimisation.
This approach is designed to test system-
level performance in service, and within design limits means observed performance feedback is vital. All connectors therefore need to demonstrate proven durability over the long term as well as the ability to tolerate high mechanical and electrical stress with no reported failures under high current conditions. In the case of never fail systems such as visionair’s, this should be the case even when delivering more than twice the rated current in some cases.
Conclusion
Connectors are an essential part of next- generation UAV design, key to power
distribution and signal routing, infl uencing weight, packaging density, signal integrity, and mechanical robustness. Lightweight, vibration-resistant connectors support the SWaP objectives central to UAV development. They help ensure consistent system behaviour in demanding operational conditions by maintaining secure mating under continuous mechanical stress and preserving electrical performance in mixed-signal environments. For companies operating in this (or similarly critical sectors), the need for never-fail designs is vital and to achieve this, connectors need to apply high-reliability, aerospace-grade connector design principles to emerging UAV applications in order to offer compact, durable interconnect solutions tailored to vibration- prone and weight-sensitive platforms. For visionair avionics across its power management systems, there is also a need for a practical balance between performance, availability and cost. This means the functionality is fl exible enough to support multiple product architectures, with proven reliability under testing and real-world deployment in high-vibration and challenging thermal environments.
https://vat.aero/
www.harwin.com
+44 (0) 1403 790 661
sales@fclane.com
www.fclane.com WE CONNECT TECHNOLOGY
fclane.com
EX-STOCK SUPPLY
COMPETITIVE PRICING
ENHANCED PERFORMANCE
UK DESIGN AND MANUFACTURE
STANDARD AND CUSTOM SOLUTIONS
DEFENCE, INDUSTRIAL AND MOTORSPORT
EXTENSIVE RANGE OF PART NUMBERS AND FINISHES
HIGH QUALITY, RELIABLE PERFORMANCE CONNECTOR ACCESSORIES
www.cieonline.co.uk
ON-LINE SHOP AND TECHNICAL SUPPORT
Components in Electronics September 2026 25
24HR DELIVERY
NO MOQ
NO MOV
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52
