Why can’t the most common, commercial-off-the-shelf (COTS) cable be used in any environment?
Cables are often the last component considered during system designs. In many situations, they’re really the system’s lifeline — if a cable goes down, the entire system can stop. For example, if the cable system used for data transmission in an automotive environment or in a spacecraft fails, the communication between the craft and mission control could be lost.
Cable reliability is based on both durability and signal integrity. The ideal cable system should be engineered to last the life of the product in any environment.
The environments that cable systems find themselves in today are becoming more challenging. A harsh environment is one in which a cable’s reliability, signal integrity, and life expectancy can be compromised. In essence, a harsh environment is where a standard or common commercial cable will not perform in that specified environment.
For example, cables are being exposed to extreme temperatures, chemicals, abrasion, and electrical noise. Additional factors can include the need for resisting, flammability, smaller diameters, and lighter materials for cable systems that last longer and cost less over the life of the system. Informed material and design choices can deliver dramatic performance to address conditions within harsh environments.
Defining Harsh Environments
Ground vehicles, space, aircraft, maritime, and industrial uses each have unique challenges and needs. For example, a maritime environment will emphasize low smoke and zero halogen materials, physical toughness, and chemical compatibility without regard to size and weight. Figure 1 outlines some of the rigors of specific applications and/or harsh environments with emphasis on the most critical stressors.
