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End-to end interconnect solutions for harsh-environment applicationsCustom military and aerospace cable assembliesand wiring harnesses
Over 50 years of custom cable assembly and wiring-harness heritageHeritage-proven products and customcapabilities position Eaton as a primarysource for harsh-environment cableassemblies and wiring harnesses for allphysical domains: air, space, sea, andterrestrialEaton can provide custom cables and wiring harnesses forturnkey design, collaborative co-development, or build-to-printprograms. End-to-end connectivity capabilities include: Application-specific solutions for high currents andvoltages, Ethernet, and RF applications Single and multiple-layer foil and braided EMI/RFI shielding Extreme temperatures, shock, vibration, radiation, corrosivemedia, vacuum, and pressures up to 20,000 PSI Integrated mechanical tow, fluid delivery, and cableseparation and release capabilities Water blocked and pressure balanced oil filled subseacablesMilitary and aerospace program heritage includes:Mobile-launch systemsShoulder-fired missile launchersNaval-weapons systemsHigh-altitude-missile defenseBallistic missilesMine countermeasuresAirborne-weapons systemsThree strategically-located facilitiesEaton offers customers three manufacturing facility optionsto meet a broad range of logistics, cost, and compliancerequirements: Camarillo, California, 116K square feet Chelsea, Massachusetts, 33K square feet Nogales, Mexico, 85,000 square feetAll facilities are certified to ISO9001:2008. The Camarillo andNogales facilities are also certified to AS9100 Rev. C.2Certifications and compliancesIPC J-STD-001 E certified solderersMACAMX NASA NHB-5300 workmanship standardsIPC620 Class III compliant assembly NAVSEA S9320-AM-PRO-020/MLDG overmoldingITAR technology control plan in placeEATON Custom military and aerospace cable assemblies and wiring harnesses
End-to-end connectivity solutions for harsh-environment applicationsTwo polyurethane overmolds and anintegral custom spring maintain the criticalcontours of this cable assembly in a naval,surface-to-air missile system.Precise positioning of cable branches and connector-mounting flanges areconfirmed by test fitting the cable assembly to the mounting rail in thisair-to-air missile application.This ICBM cable assembly features an Eatondesigned custom connector, MIL-DTL-38999connectors, induction soldering and continuousnylon-fabric braiding.Rectangular and mil-circular connectors andelectromechanical components are integratedwith a mounting bracket in this anti-aircraft andanti-missile weapons system solution.Tight-tolerance design and assemblysupports fitting this seven micro-Dconnector solution into a confined space,naval-weapons-system application.Design and assembly of this weaponssystem solution includes a multi-branchlaced harness, polyurethane overmoldingand a mounting bracket.EATON Custom military and aerospace cable assemblies and wiring harnesses3
Accelerated design-to-delivery cycle timesEaton combinesadvanced engineeringtools with an extensivearray of manufacturingresources to quicklydeliver custom cableassemblies and wiringharnesses4Eaton’s engineers leveragetheir in-depth understanding ofproduction processes to improvemanufacturability.High-speed planetary cablereliminates minimum cablerequirements and supports helicallyand contra-helically laid cables.In-house designed braiders supportany combination of foil and braidshielding to provide 90% opticalcoverage.Heritage-proven standard connectorsand custom capabilities streamlineend-to-end interconnect-solutiondevelopment.Assembly certifications andcompliances include: IPC J-STD001E, IPC 620, NASA-STD-8739.4,MIS-20887 and MPD-7011.Insourced and outsourced moldcapabilities support a wide range ofstandard and custom requirements.Overmolding resources include over20 compression and transfer moldingmachines.Test capabilities include DWV, IR,RF, and quick-ramp-rate temperaturecycling.EATON Custom military and aerospace cable assemblies and wiring harnesses
In-house planetary cabler eliminates minimum cable requirementsEaton’s in-house planetary cabler facilitates high-speedcable winding and incorporates taping heads that can applyshielding foils, Mylar tapes and binders during the cablingprocess and reduce cable manufacturing time and cost.Eaton’s in-house planetary cable winderAdditional high-speed-winding capabilities include:supports accelerated delivery schedules, Supports helically and contra-helically-laid configurations toprovide maximum cable flexibility Accommodates over 36 feed positions depending oncomponent size and construction Produces 1/8” to 1-1/2” outside diameter cables utilizing28AWG through 1/0AWG conductors or pairsshort production runs, and produces awide range of cable configurationsCustom-wound cable, up to 1-1/2” outside diameter, exits theplanetary winder above the control panel on the left.Over 36 wires can be concurrently wound to support a widerange of customer requirements.Eaton’s in-house cable winding capabilities canreduce manufacturing time and cost for multi-cableconfigurations such as the solution depicted to theleft which contains 8 custom-cable assemblies. Thisend-to-end interconnect solution also includes: 15 overmolded connectors 3 backshells and 2 molded junctions An integral energy chain assembly with bracketsEATON Custom military and aerospace cable assemblies and wiring harnesses5
Lacing and overbraiding design optionsEaton’s custom-cable capabilities can support an extensivearray of harsh environment wire lacing, any combination offoil and braid EMI/RFI shielding, and protective overbraidingrequirements.In-house capital equipment includes customized braidingmachines that can optimize braid angles to facilitate 90%optical coverage and effective EMI protection for a widerange of cable and wiring harness sizes and complexities.Wire lacing processcapabilities include: NASASTD-8739.4, MIS-20887,MPD-7011, and IPC-620Fabric and metal braidingfeatures include continuous,uniform coverage evenaround branch junctionsFoil shields include aluminizedMylar and MuMetal. Braidedmetals include: Nickel, silver, or tin-coated copper Tinned copper-clad steel Stainless steel AluminumBraided textiles include:Kevlar, Nomex, Nylon,Polyethylene, Polyester,and Teflon.This harness provides 384 connections and incorporates acontinuously-braided EMI shield and Nomex overbraiding,15 connectors, 8 ferrites, 2 switches and a mounting flangeinstalled over a slip-ring assembly.6Customized braiding machines facilitate optimization ofbraiding coverage and angles to support application-specificmechanical and EMI/RFI requirements.EATON Custom military and aerospace cable assemblies and wiring harnesses
Jacketing and overmolding capabilitiesJacketing materials include: Blown-on EPDM, polyurethaneand neoprene Shrunk-on polyolefinBraided Kevlar, Nomex,nylon, polyesterNAVSEA S9320-AM-PRO-020/MLDG certified processesprovide void-free overmolds Convoluted tubingOvermolding materials include: Transfer-molded EPDM, Hypalon,Neoprene and Viton. Press-molded epoxies, polyurethanes,and siliconesSpecialized primers facilitate maximum overmold-to-substrateadhesion to ensure separation-free bonds in harsh environments.Jacketing and overmolding capabilities extend from cableassemblies utilizing standard military connectors (depictedabove) to custom solutions such as the 4160V connectorsdepicted to the right.This high-voltage cable assembly was designed to providepower to a high altitude, ballistic-missile-defense system.A void free, 6.5” (165mm) diameter by 10.5” (267mm)length overmold is facilitated by tooling that is designed andmachined in-house. High-voltage insulation and shieldingperformance is verified by corona testing.Eaton’s inventory of overmold cavities includes MILDTL-38999, MIL-DTL-83513 micro and MIL-DTL-24308D-subminiature. Accelerated custom-mold development issupported by a combination of insourced and outsourcedmold-making resources.An extensive array of overmolding equipment includes: Eighteen small-form-factor (4”to 6” stroke)compression-molding machines Five transfer-molding presses with 15 to 75 ton capacities Low pressure, hot-plate-molding equipmentEATON Custom military and aerospace cable assemblies and wiring harnesses7
For additional information Visit www.eaton.com/interconnect Call 805.484.0543 Email cicustomer.service@eaton.comEaton1000 Eaton BoulevardCleveland, OH 44122United StatesEaton.comCustomer Service750 West Ventura Blvd.Camarillo, CA 93010Phone: 805.484.0543 or800.840.0502www.eaton.com/interconnect 2014 EatonAll Rights ReservedPrinted in USAPublication No. BR800002ENJanuary 2017Eaton is a registered trademark.All other trademarks are propertyof their respective owners.
compliances include: IPC J-STD-001E, IPC 620, NASA-STD-8739.4, MIS-20887 and MPD-7011. Eaton combines advanced engineering tools with an extensive array of manufacturing resources to quickly deliver custom cable assemblies and wiring harnesses Eaton’s engineers leverage their
