New Combat Systems Set to Conquer the Future

By Contributed Article | November 19, 2024

New battlefield strategies and combat systems that network dismounted soldiers for “any-sensor, any-shooter” tactics are driving technological changes in digital gear needing advanced interconnects.

By Matt McAlonis, Engineering Fellow, Aerospace Defense and Marine, TE Connectivity, and Franck Kolczak, Senior Business Development Manager-Defense Market, TE Connectivity

A joint warfighting concept called Joint All-Domain Command and Control (JADC2), signed into law in 2022, is taking advantage of digital technologies in the U.S. military services. Interfaces that resemble real-time-strategy (RTS) games and utilize virtual reality (VR) headsets are now part of real world combat systems.

Connectivity for multi-domain operations

The connectivity challenges in implementing the JADC2 concept are immense. JADC2 aims to network every soldier, intelligent device, and weapons platform from all five military branches (air, land, sea, space, and space). The goal is to enable a distributed command that fulfills mission goals using any available resource, anywhere. For example, the U.S. Army is training soldiers with helmet-mounted head-up displays (HUD) that use augmented reality to sharpen their situational awareness. A militarized version of commercially used mixed-reality smart glasses built by Microsoft, these headsets provide an Integrated Visual Augmentation System (IVAS) that displays thermal and 3D images, directional compass waypoints, and weapon crosshairs — while letting the soldier see terrain through the lens without smartphone-type distractions.

A soldier can simple flip down a transparent screen on their helmet and use the screen to scan the landscape and identify friend or foe. The technology also reveals data about the health and readiness status of the squad. Biometric sensors embedded in the uniform and other wearable gear can detect vital signs, amount of rest/sleep, hydration, focus, alertness, blood sugar, metabolic status and energy reserve, and altitude adaption, as well as ammunition supplies, battery levels, and potential exposure to toxic chemicals and materials. Algorithms can take data from the environment coupled with data from biometric sensors and extrapolate the need for supplies and other reinforcements.

IVAS benefits the larger battlefield by supplying tactical information — such as recognizing an enemy aircraft missile launcher — and then transmitting coordinates to the network so friendly assets can quickly destroy it.

Protecting soldiers with sensors

Commercial off the shelf (COTS) products are typically not designed for rugged environments or for demanding application size, weight, and power (SWaP) requirements, and thus cannot meet the connectivity challenges of these new applications. To function as an integrated combat platform, IVAS utilizes the U.S. Army’s Adaptive Squad Architecture (ASA). Not an open architecture, ASA specifies how components interconnect in a network where large scale, very secure data exchange is used to prevent enemy access. Supporting any sensor, any shooter network communications, ASA also aims to trim the weight of soldier gear, which often tips the scales at over 120 pounds.

Connecting with a Department of Defense (DoD) cloud for data analytics using artificial intelligence (AI) and machine learning (ML) can provide real-time answers to questions such as, where is the adversary? Where are my troops? Are my troops prepared to engage with adequate armaments and supplies?

Connectivity underpins combat systems

Significant bandwidth and SWAP challenges are driving major improvements in connectivity products. Batteries, cables, and devices must all interconnect with other soldier components. That includes the increasing number of sensors and computing devices embedded in soldier gear that function in an Internet of Military Things (IoMT) or Internet of Battlefield Things (IoBT). From pedometers in boots to heart-rate sensors in chest armor, the sensors and computing devices worn by soldiers can supply valuable context-aware biometrics about a soldier’s physical condition. Yet, the sheer complexity of enabling individual, squad, command, and cloud connectivity during combat presents daunting challenges to the military electronics designer.

O.C.H. Micro Circular Connectors from TE Connectivity

To support these advanced applications and enhance the next generation of battlefield technologies, a host of advanced antennas, sensors, interconnect, wire and cable, and harnessing accessories are available. To start with, consider the connectivity components used at the physical layer of the data transmission link.

O.C.H. micro circular connectors from TE Connectivity address a host of connectivity challenges, whether the electronic devices are worn on a human or fastened on a vehicle. Originally developed for the U.S. Army’s Nett Warrior program, these small, lightweight connectors were designed for future soldier gear, including soldier vest cables, batteries, antennas, communication systems, power hubs, radios, and military vehicles.

Mini-ETH Single Pair Ethernet can use shielded 369 Series Connectors with up to 37% smaller cross-sectional area compared to traditional micro circular connectors

The ruggedized design employs a push-pull breakaway coupling mechanism that enables quick connections and single-action disconnections. O.C.H. micro circular connectors meet the rigorous mechanical and performance requirements of MIL-STD-810G. Robust aluminum shells are available with both all-over electroless nickel plating and selective anti-reflective black zinc/nickel plating, thermoplastic inserts, six or seven gold-over-nickel-plated copper alloy contacts, and multiple keying options to ensure proper mating in demanding battlefield environments. Moreover, the aluminum shell and thermoplastic inserts provide a small, lightweight package for soldier-worn gear. Connectors are temperature rated from -18 °C to +71 °C when crimped to a 22 AWG wire and are also resistant to shock and vibration and intermateable with many other Nett Warrior products.

SWaP strategies reduce cable bulk

High-speed data link cables for combat systems must transmit signals and data with high fidelity, supply power to connected devices, and withstand harsh environments. Of course, Ethernet protocol makes it easy to route data with nearly everything, everywhere. But for soldier gear, bulky eight-wire Category 6 cables are out of the question. Fortunately, the Ethernet physical (PHY) layer can use two wires in a single pair Ethernet (SPE) configuration, commonly known as 100BASE-T1. Robust SPE cable is being positioned as a platform for the Industrial Internet of Things (IIoT). To meet aviation-electronics reliability requirements, TE’s Mini-ETH SPE system references the ARINC 854 standard. Using only one pair of wire, Mini-ETH assemblies offer substantial size, weight, and cost savings over traditional custom designs using three or four pairs of wires per Ethernet cable.

Mini-ETH cable is qualified for 200 MHz and 100 Mb/s operation at 15 m (49 ft.) link lengths, TE has a roadmap to support 1 Gb/s and 10 Gb/s data speeds at 40 m (131 ft.) link lengths and frequencies over 750MHz, as well as new connector designs to support higher frequencies and speeds. A Power-over-Data-Line version is also planned.

Originally introduced for screens, sensors, data hubs, and other electronics on aircraft, compact Mini-ETH cables and connectors are also candidates for new combat systems where size and weight reductions can be beneficial.

Mini-ETH Single Pair Ethernet can use TE’s shielded 369 Series Connectors with up to 37% smaller cross-sectional area compared to traditional micro circular connectors.

For back-end military and defense applications such as missile-warning, radio-communication, remote-weapon, and fire-control systems, Category 7 Ethernet cable offers 100 Gb/s speeds over 15 m (49 ft) links and reverts to 10 Gb/s at longer distances. TE Raychem Cat 7 cables are individually shielded, 4-pair cables that comply with IEC 61156-6 requirements and use 26 AWG wire as required in certain military and aerospace applications.

Battlefield advantages

In today’s world, dismounted soldiers in the field rely upon instant informational superiority on the battlefield. The connectors, cables, and accessories for these soldier systems are available now. Experienced manufacturers can also engineer products that meet evolving needs and assist the defense industry to develop solutions for future challenges.

For more information about combat systems, visit TE Connectivity.