By Admin
2024-12-13 06:49:16
Military waterproof wiring harness
Military waterproof wire harness is a special cable assembly designed for military equipment, combining high-strength protection and adaptability to complex environments,Military waterproof wiring harnesses need to ensure stability and reliability in extreme environments. Their special requirements cover multiple dimensions such as materials, structure, performance and testing, as follows:
Material properties
- Corrosion resistance: Nickel-plated copper wires, stainless steel connectors and other materials are required to resist salt water and chemical corrosion.
- Temperature resistance: The material must withstand extreme temperatures of -40°C to 125°C to ensure stable performance in high/low temperature environments.
- Flexibility: Use twisted core or winding design to improve the wire harness's resistance to stretching and twisting, and adapt to frequent mechanical movements.
Sealing material
- Waterproof plugs and seals must be made of silicone or fluororubber, which are resistant to high temperatures, aging and UV rays.
Waterproof level
- The connector must meet the IPX7 (short-term immersion in water) or IP68 (continuous immersion in water) protection level, and the core components adopt a radial sealing structure (such as O-ring + potting glue), Process control.
- Crimp process: The waterproof terminal needs to be crimped with a special mold to ensure that the size after crimping matches the connector.
- Welding protection: The solder joint needs to be wrapped with a heat shrink tube to prevent the copper wire from being exposed and affecting the sealing.
Comparison between military waterproof wiring harness and ordinary waterproof wiring harness
| Contrast Dimensions | Military waterproof wire harness | Ordinary waterproof wiring harness |
| Material and Conductor | Nickel-plated copper wires, stainless steel connectors, and fluororubber seals are used for stronger corrosion resistance. Conductors are mostly multi-stranded copper wires to enhance flexibility and tensile strength. | Mainly ordinary copper conductor or PVC insulation layer, some models use ordinary rubber seal, which has weak corrosion resistance. |
| Protection level | It must meet IP68 (continuous immersion) or higher protection standards, and key components must be double-sealed with O-rings and potting glue. | Generally IP67 (short-term immersion in water) or below, relying on a single seal or heat shrink tubing for protection. |
| environmental adaptability | Temperature range: -40℃ to 125℃, resistant to vibration, impact, salt spray and electromagnetic interference (compliant with GJB599A) | Temperature range: -20℃ to 85℃, only basic waterproof, limited vibration and corrosion resistance. |
| Structure and redundancy design | Adopt radial waterproof structure (such as cross-linked polyethylene insulation layer) and redundant connection design to reduce the risk of single point failure. | It is an axial waterproof structure (such as ordinary rubber sheath), with no redundant design, and the sealing depends on the consistency of the process. |
| Mechanical strength and lifespan | The sheath is made of nylon reinforced glass fiber or PBT material, with a tensile strength of ＞50N and a plug-in life of ≥500 times. | Ordinary rubber or PVC sheath, tensile strength ≤ 30N, plug-in life about 200 times. |
| Standards and Certifications | Need to pass military certification such as MIL-STD-810G (environmental adaptability) and MIL-DTL-5015 (connectors) | Complies with common industrial standards (such as IEC 60529) without strict military regulations. |
| Typical application scenarios | Submarines, armored vehicles, aircraft and other extreme environments (high humidity, strong vibration, electromagnetic interference) | Civilian equipment, outdoor lighting, shallow water electrical appliances and other common humid environments. |
Military waterproof harness application scenarios
Underwater equipment: such as submarines and underwater robots, which require high-level sealing and corrosion-resistant design.
Field equipment: adapted to dust, rainstorms and extreme temperature environments, relying on wear-resistant and anti-aging harnesses.
Military waterproof harness testing and certification
Air tightness test
Pressure test (such as 20kPa inflation and pressure holding for 10 seconds) is performed through the intelligent sealing detection system to verify the waterproof performance.
Standard certification
Must meet military regulations such as MIL-STD-810G (environmental adaptability) and MIL-DTL-5015 (connectors) to ensure reliability throughout the life cycle.
