Not totally unlike those used in other industries such as construction or automotive, military electrical systems are typically designed for mobility, but must meet more highly adaptable specifications in order to perform in many diverse and extreme conditions and situations.
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From desert heat and freezing snow to high altitudes and deep ocean water, military operations can take place in some of the most demanding environments in the world.
Meanwhile, the devices, vehicles, and weapons they use have to be ready to be deployed across the globe at a moment’s notice.
Because it can literally be a matter of life and death, harnesses and cables that military personnel rely upon to operate that equipment must be as dependable as possible.
From aircraft and ships to ground vehicles, drones, and communication systems, harnesses, solar power, and cables are essential to many military applications. Without them, critical military operations could be compromised.
More so than any other industry, military harnesses and cable assemblies must be designed and manufactured to meet a wide variety of challenges including:
While military wire harnesses and cable assemblies perform essentially the same functions as those in other industries — transmitting critical power and data to and from electrical devices — they have to be especially good at what they do.
No matter your industry, CAI’s custom wire harnesses and cable assemblies are built to your exact specifications and to perform up to the highest standards. For all your electrical system needs, reach out to the experts at CAI today.
Extreme reliability and durability are of the highest priorities, so the materials and processes used to create military wire electrical systems must be of the highest quality and their construction done by expert hands. Strength, flexibility, cost-effectiveness, and electrical compatibility are among the key features manufacturers look to optimize.
Precision and attention to detail are essential in the design, production, and installation, especially because military harnesses and assemblies are subject to the strictest of regulations to which OEMs must adhere.
Developed to ensure that all parts used for military purposes meet a uniform level of quality in performance and reliability, Military Specification (MIL-Spec) is a military standard that regulates the design of electrical devices built for military applications. MIL-STD-454 is the specific requirement regarding electronic equipment used in a military capacity. While there are numerous Mil-Spec standards, the following are some of the more commonly used Mil-Spec standards for wire harnesses and cables assemblies.
Designed for intense aerospace conditions, this wire type is commonly used for aircraft engine controls and electrical components operating in severe elements and moisture-heavy areas.
Able to withstand extreme temperature and voltage ratings, this wire type is insulated with materials like PVC, PTFE, Polyalkene-PVC, and ETFE. Designed specifically for each product, this wire comes with different options. For instance, M/4 is suitable for harnessing, appliance wiring, and power supply, while M/5 is meant for electronics exposed to high temperatures.
Used for severe environments with high vibration and flame exposure, this type is suitable for critical aircraft circuits.
For low-tension military applications, this cable is moisture- and abrasion-resistant and flexible even at low temperatures. Typically used in trucks, tanks, and other ground vehicles, this type is also available in different options to fit different product requirements.
A general-purpose wire ideal for abrasion, impact, and chemical exposure, and spanning applications across military, aerospace, and industrial, this wire family features tin-plated copper conductor insulated by PVC and a nylon jacket.
CAI is your trusted source for custom and confidential military wire harnesses and cable assembly manufacturing. We design, test, and manufacture military wiring harnesses that withstand the extreme conditions and perform reliably when every second counts.
Since , CAI has delivered high-quality custom manufacturing solutions — from wire harnesses and cable assemblies to box builds and electromechanical assemblies — to satisfied customers across the globe. Offering a personalized approach to every project, CAI partners with clients to create innovative products that exceed industry standards.
Review of three test use cases within a single defense contract company: Test evaluation of returned product; testing complete systems; and design of test cables. Read more (html)
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Mar 20,A review of some of the more unusual applications we have encountered over the years. Read more (html)
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Without performing these checks, you run the risk of releasing or accepting faulty product. It is important to know and understand the parameters against which your cable or harness has been judged to have “passed”. Read more (html)
Ready to purchase a new tester? Ask these questions of your potential supplier.
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We show that it is not necessary to apply voltage to shield conductors to accurately test insulation resistance as long as the shields remain at zero volts when the other wires are tested at high voltage.
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Probar la continuidad y aislamiento utilizando probadores de cables multi conductores es una parte esencial del proceso de trabajo. Las pruebas exhaustivas antes y después de la instalación reducen las probabilidades de fallas del dispositivo, incluyendo eventos catastróficos como incendios e inundaciones. En este articulo introducimos un entendimiento básico de lo que implican pruebas exhaustivas de continuidad y de HiPot.
Leer mas (html)Testing continuity & HiPot using multiconductor cable testers is an essential part of the workflow. Thorough testing prior to and after installation reduces the likelihood of device failure including catastrophic events such as fire. It is simply not sufficient to rely on “glow-wire” specifications to prevent fire. In this article we introduce a basic understanding of what ‘thorough’ continuity and HiPot testing entails.
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Revised Feb 14,Our dependence on complex systems in modern manufacturing leaves us vulnerable to unexpected process failure that may have expensive consequences. While we cannot foresee the future, our awareness of failure modes should lead to simple preventve measures. Employ these precautions to help avoid preventable accidents that extract a heavy cost in time and inconvenience to correct.
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Revised Feb 7,A cable tester manufacturer's approach to automate test, fault isolation, labeling, and documentation to ensure test consistency and reduce susceptibility to human error.
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Learn how parasitic capacitance can affect your safety and the accuracy of your results when testing cables longer than 10ft.
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What to look for in a tester when creating a smart cable & harness assembly and test line, especially when following a mixed-model manufacturing process.
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A How-To Guide: Precision resistance measurements of less than 0.1 Ω reveal wiring defects not visible to less sensitive measurements. Use this measurement technique to improve cable quality and reliability.
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A must-read for makers of robotic systems: Cables in motion experience fatigue causing complete or intermittent failures whether or not that motion is constant. Learn how cable and harness test systems can easily identify and pinpoint the source of even the most elusive intermittent failure.
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What are the alternatives to the CableEye brand and how do they compare?
Who benefits from using the system?
How does cable and harness testing with a CableEye test system increase productivity?
Can all cables/connectors be tested ...?
How much time can be saved ...?
How much more productive will a user be ...?
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Learn how to choose a cable & harness tester that remains relevant as product design changes in addition to providing fast, reliable, accurate results. See how it can improve productivity even beyond the production floor.
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