Are you an engineer looking to spec out a military-grade project that needs an airborne power supply? When it comes to powering military aircraft, reliability is essential. Mission-critical equipment with power sources typically have EMI (electromagnetic interference) filtering to protect against malfunctions.
To handle rugged environments, military-grade power supply systems must be designed for a wide range of storage temperatures, altitudes, and humidity levels. They must be built with vibration and shock protection and comply with all military requirements and standards. In this guide, we’ll go over the necessary specs for a military-grade airborne power supply.
All military-grade power supplies must perform consistently despite challenging conditions. Because they power critical equipment, they must be malfunction-proof. The specific features required will vary depending on the environmental conditions where the power supply will be used — on air, land, or sea.
Airborne power supplies must be ruggedized for both manned or unmanned environments, across various altitudes and environments. Their role is to support the precision electronics operators rely on for a successful and safe mission. Examples of aerospace industry electronics include:
A reliable power source is essential to all military and aerospace operations, from surveillance missions to cargo resupply. Because modern aircraft operators use complex technology, their aircraft needs a power source that can support all necessary functions. Modern aviation power supplies require greater current at low voltages and must be designed to fit exact size, weight, and hermeticity specifications.
To ensure their reliability, all military-grade power supplies must meet the highest standards. Some of the military standards that apply to aircraft power supplies include MIL-STD-704, MIL-STD-461, and MIL-STD-810. These standards monitor aircraft electrical systems, electromagnetic interference, and environmental conditions respectively.
MIL-STD-704 ensures that an aircraft’s power supply is compatible with the technology that’s powered by it. It measures specifications like acceptable voltage levels, acceptable voltage variations, emergency power characteristics, and the power system’s response to abnormal conditions like power spikes.
Not every aircraft has the same compliance requirements — C-UAS power supplies must meet additional standards such as MIL-STD-1275 and MIL-STD-1399 before they’re considered mission-ready. Because C-UAS technologies require additional equipment to control unmanned aircraft, these standards regulate power and compatibility for military vehicles and ships, respectively.
To perform well at a military-grade level, airborne power supplies are held to stricter standards than general power supplies. They must meet demanding specifications, which vary depending on the aircraft. Some of the unique features and benefits of aerospace military power supplies include:
Because aircraft have limited space and weight allowances, power supplies for military aircraft must generate a high-power volume for a relatively small power unit. Finding ways to reduce the size of a power supply while increasing its energy production can be challenging. However, technological advances continue to make it easier to meet these unique requirements.
Aircraft encounter harsh conditions, with varied temperatures, humidity, and altitude. For safety reasons, airborne power supplies must function efficiently regardless of changing conditions. They should also be equipped to handle vibration and shock without malfunctioning or being damaged.
Military-grade power supplies are intentionally built to operate for a long time before needing to be replaced. They’re made of high-quality materials and designed to be energy efficient so they give off less heat while in use. Prioritizing efficiency helps to reduce the overall power consumption in an aircraft.
To ensure the safety of operators and aircraft, military-grade power supplies are designed with many built-in protections. They’re made to handle short circuits, high temperatures, electrical surges, and more. Before being sold, they are extensively tested to ensure they meet all requirements and can safely power military aircraft.
MIL-STD-704 covers the requirements for power supplies in military aircraft in flight, landing, taking off, or on the ground. When designing and selecting a power supply for your military-grade airborne project, you must ensure compliance with all MIL-STD-704 requirements. You can learn more about the requirements and compliance testing in handbooks MIL-HDBK-704-1 through -8.
Because military operations require high performance and unique specifications, many military-grade power supplies are customized to solve specific power challenges. Custom aerospace power supply features can include form, mounting options, and the number and type of input-output. Sometimes sound is also a concern.
The power supply of a military aircraft is arguably its most important equipment. Choosing the best power supply for your air-based operation depends on the aircraft’s specifications and how it will be used. For example, the power needs of a C-UAS are different from those of a manned aircraft.
Consider the electrical components of your aircraft — the power capacity of your airplane power supply needs to be strong and stable enough to support all systems without interruption. Your power supply should be tested for environmental concerns, such as vibrations, moisture, and temperature fluctuations. It should also effectively resist electromagnetic interference (EMI).
The ideal power input-output depends on your system. While some aircraft use DC-DC, others require an AC-DC connection. If off-the-shelf forms and racking aren’t the best options, consider designing a custom power supply. You can adjust the form for a better fit and change the power supply racking for maximum protection.
For designing and manufacturing your power supply, it’s essential to work with a company you trust. An experienced organization can connect you to the resources you need for a successful power supply that’s reliable, works efficiently, and meets all required specifications. They can also guide you through compliance, ensuring the final product meets all military-grade standards.
At Advanced Conversion Technology (ACT), we’ve been serving the United States military since 1981 with mission-ready, ruggedized power solutions. We have the capacity to design, manufacture, and test military-grade power solutions all under one roof in Middletown, Pennsylvania. All our power supplies are proudly made in the United States.
We provide off-the-shelf AC-DC and DC-DC power supplies. If you need custom solutions, we have extensive experience designing power supplies that meet varied client specs. Our build-to-print services are ideal for clients who have already engineered their design and still need a trustworthy manufacturing partner.
At ACT, our power supplies are designed to meet all required military-grade requirements, such as MIL-DTL-704, MIL-STD-810, and MIL-STD-461 standards. We prioritize the highest quality management with a system that’s AS9100D and ISO 9001:2015 certified. It’s our mission to provide mission-critical power solutions you can count on to perform and protect.
Request information on a custom power supply or learn more about our off-the-shelf solutions today!
