In harsh environments, a failed connector can halt critical operations instantly. A UGV can lose its live video feed in the middle of a mission. A mining excavator can shut down deep underground. A railway system can lose vital signaling data. Reliability is critical.
Connectivity solutions face a number of environmental threats that can lead to failure:
Vibration and shock: Military vehicles, mining equipment, and high‑performance automotive systems generate continuous vibration and sudden impact that can loosen traditional locking systems, causing intermittent contact or complete disconnection. Connectors used under these conditions require robust locking mechanisms, such as a Ratchet Locking System (RLS), to remain secure. Fischer UltiMate™ Series size 15 RLS connector can withstand an exceptional 37.8 Grms of random vibration and 300 g of shock amplitude, providing unmatched security for extreme mechanical stress.
Water exposure and submersion: Interconnects exposed to humidity, water ingress, or full submersion, such as the case with unmanned underwater vehicles and underwater scientific instrumentation, can short-circuit and damage device functionality. Connectors used in this environment must be ultra-sealed and watertight to prevent leakage into or out of the equipment. Fischer UltiMate™ Series delivers best-in-class protection with IP68 sealing, rigorously tested for 2 meters of immersion for 24 hours, mated or unmated, and IP69 resistance to high pressure, high temperature water jets.
Temperature extremes: Wide temperature ranges cause materials to expand and contract, creating stress that can lead to microcracks and loosening. Applications exposed to rapid temperature swings, including aerospace, oil and gas, defense, and medical devices, need connectors that stay mechanically and electrically stable in these conditions. For instance, in surgical settings, connectors and cable assemblies must tolerate repeated autoclave sterilization at 250°F for 30 minutes or 273°F for 13 minutes. The Fischer UltiMate™ Series exceeds these demands with an operating temperature range of 67°F to 275°F, ensuring reliable performance from extreme cold to high heat.
Chemical exposure: Industrial solvents, fuels, cleaning agents, and salt spray, common in naval, mining, transportation, and manufacturing environments, can accelerate corrosion, leading to higher contact resistance and eventual failure. Connectors built with corrosion-resistant materials, such as protective plating, provide the necessary protection. Fischer UltiMate™ Series connectors offer an industry-leading 1,000 hours of salt spray resistance to safeguard against corrosion in harsh chemical environments.
Harsh environment connectors must do more than merely survive. They must excel. Modern applications demand several critical capabilities:
High-speed data transmission: Unmanned vehicles need real-time video feeds, and railway networks rely on instant sensor data for split-second decisions. Connectors must provide fast, reliable data transfer without compromising durability.
SWaP optimization: Size, weight, and power matter in UAVs and portable systems. Connectors must be compact yet high-density and high-speed.
Rapid, tool-free mating: In field operations and combat zones, interconnects should couple and uncouple quickly and securely, even while wearing gloves. A ratchet connector can be uncoupled with less than 2 turns.
Traditional locking systems can loosen under vibration. Fischer Connectors solved this with the industry’s most advanced Ratchet Locking System (RLS) in the UltiMate™™ series. Proven on the most demanding vibration profiles typical of armored vehicles, heavy UAVs, and rail systems, it reliably prevents accidental unmating caused by shock, recoil, off-road mobility, or turbulence.
Performance That Redefines Ruggedness
In Fischer UltiMate™™ size 15 contact configuration, our RLS system fits up to 27 pins in a receptacle only 25.8 mm in diameter and withstands 37.8 Grms of random vibration. This exceeds vibration levels in most ground vehicles and many aerospace applications. It also handles shock loads up to 300 g, providing unparalleled protection from unexpected unmating.
This strength comes without sacrificing usability. The RLS mechanism’s easy mating is a major advantage in tight spaces or when operators wear protective gear. Mating and unmating requires only less than two rotations, making it the fastest, most intuitive, and most secure solution for demanding field conditions.
Durability and endurance go further with our high mating-cycle rating (3,000), meeting the needs of harsh environments where frequent connection and disconnection are common for maintenance or reconfiguration.
Solving the USB-C Challenge
The rise of USB-C as a universal standard for data, video, and power transmission created a new challenge. How do you bring this convenient, high-performance interface to harsh environments?
Fischer Connectors tackled this challenge by engineering the world’s most advanced ruggedized USB-C solution incorporating RLS technology. The result maintains full USB-C functionality (including high-speed data transfer, video transmission, and power delivery) while meeting military and industrial environmental standards.
The most advanced technology is only as reliable as its most vulnerable connection. And in harsh environments where lives and millions of dollars hang in the balance, Fischer Connectors ensures our connectivity solutions are engineered to perfection, delivering the best performance, the highest reliability, and the most innovative designs in the industry.
July 8, 2025 · 4 min read
