How custom solutions help meet complex performance requirements across demanding aerospace applications
In aerospace engineering, every application presents its own combination of performance requirements, environmental conditions and design constraints. From commercial aviation and defense to space launch, satellites and ground-test applications, temperature sensors and cable and harness assemblies must deliver reliable performance in environments where failure is not an option.
Conax works with aerospace OEMs, Tier 1 system suppliers, engine and propulsion companies, MRO/PMA organizations and emerging space companies to develop solutions for applications throughout aircraft, engines, propulsion systems and spacecraft. That experience gives our engineers insight into not only how these components need to perform, but also the manufacturing, supply chain and qualification challenges aerospace customers face.
Custom engineering makes the difference
Aerospace customers are increasingly looking for qualified suppliers that can provide an alternative source for critical components without sacrificing quality, performance or manufacturing capacity. At the same time, aggressive cost and lead-time requirements make it important to work with a supplier that understands the complexities of aerospace manufacturing.
Conax combines temperature sensor and cable and harness expertise with capabilities that include welding, braiding, crimping and coiling. Our design engineers can also work directly with customers to address issues with existing designs or develop new solutions around specific application requirements.
That collaborative approach can make a difference early in the design process. For a recent aerospace test-stand application, a customer approached Conax with specifications for an RTD. Rather than simply quoting the requested component, Conax design engineers developed two options. The first used a monolithic design with the RTD and connector welded together. The second incorporated a mineral-insulated metal sheath (MIMS) with the connector positioned several inches away from the RTD to help protect it from the heat source. By anticipating a potential concern based on experience with similar applications, the engineering team gave the customer two viable approaches to evaluate based on the needs of the system.
Designing for performance
There is no single formula for aerospace sensor design. Every application presents its own combination of environmental conditions, performance expectations and design constraints. Success comes from understanding how precision, weight and reliability influence one another—and engineering a solution that balances all three.
By partnering with an experienced engineering team early in the design process, manufacturers can improve measurement performance, increase reliability and develop sensor solutions that are built to perform in even the most demanding aerospace environments.
Engineering for harsh environments
Conax has experience developing temperature sensors and cable and harness assemblies for applications throughout commercial, military and space systems. Applications include engine sensors and harnesses for exhaust gas temperature (EGT) measurement, engine vibration harnesses, fuel tank inerting systems, fuel tank RTDs, heated water drain masts, brake temperature sensors and air inlet sensors, among many others.
Our experience extends beyond the engine. Conax has worked on cable and harness designs for aircraft seating and monitors, overhead lighting and oxygen systems, as well as thermistor designs for heating and cooling within air duct systems. For space and ground-test applications, Conax supports temperature measurement and interconnect requirements for rocket propulsion, cryogenic systems, propulsion test stands and satellite propulsion systems.
Designing for these environments requires careful consideration of every component within the assembly. Depending on the application, components may experience continuous vibration, rapid thermal expansion and contraction, extreme operating temperatures, pressure changes and mechanical shock.
Conax supports these requirements with aerospace quality and manufacturing capabilities that include AS9100 and ISO 9001 certification, IPC/WHMA-A-620 and J-STD workmanship capabilities, calibration capabilities and a range of inspection and testing methods, including X-ray inspection, helium leak testing, cryogenic testing and vibration testing.
Reliability beyond the laboratory
A sensor that performs well during initial testing must continue performing throughout years of operation. Unexpected sensor failures can increase maintenance costs, create unnecessary downtime and complicate troubleshooting efforts. In aerospace applications where access is limited or replacement is costly, reliability becomes just as important as measurement accuracy.
If your aerospace application requires a temperature sensor or cable and harness solution engineered for demanding conditions, talk to Conax about your specific requirements.