Successful missions depend on aircraft platforms that use reliable, long-lasting MIL-STD-1760 umbilicals. But, our customers have told us that they often have to replace standard umbilicals using screw-on lanyard, quick-release connectors. Why? Because they’re stiff, hard to handle and don’t withstand pylon installation or operation. Maintenance is time-consuming and costly because it involves removing many aircraft components to replace the damaged umbilicals with new ones.

Gore offers the only sealed hybrid solution proven over time to solve all these problems - an affordable, easy-to-install umbilical with a connector system that doesn't fail when installed or during operation.

GORE MIL-STD-1760 Assemblies with the L3Harris, Field Replacement Connector System? (FRCS?) are the only solution proven to guarantee safe operations with a low bend force over wide temperatures. They’re also proven to protect against electromagnetic interference (EMI) with at least 85% optical coverage. Not only that, our MIL-STD-1760 shielding assemblies have a life beyond 100,000 flexes in harsh aerospace conditions without ever failing to do their job.

Robust and highly flexible, our assemblies can be easily installed in limited spaces of aircraft pylons. They’re available in a variety of wire types with a smaller cross-sectional diameter compared to standard umbilicals. They can be easily attached and removed from ASI (Aircraft Store Interface) and MSI (Mission Store Interface) while operating in an NBC (Nuclear Biological Chemical) environment. Our assemblies reduce maintenance, downtime and product lifecycle costs because they don’t have to be replaced after each use.

Robust, highly flexible layout of GORE MIL-STD-1760 Assemblies, Class 1 (FO) Version.

We worked with L3Harris to compare the performance of our MIL-STD-1760 cable assembly with their FRCS? against standard umbilicals that use screw-on MIL-STD-38999/31 lanyard connectors. We configured a simulator on stores with racks adjusted to represent various pylon stations accurately, including retention methods. Then, we captured the data to validate umbilical connector loads and store velocity during ejected pit releases.

Our results showed that 1 out of 10 new standard umbilicals separated within the specification limit after 100 drops. Also, 50% of the umbilicals were unserviceable after only 3 drops, and 25% failed to disconnect at all and ended up in the pit. But, our assemblies with the MIL-STD-1760 connector pinout from L3Harris delivered consistent disconnect loads and can guarantee 100 fully high-speed instrumental drops.

We thoroughly test and qualify our assemblies according to the MIL-STD-1760 specification, MIL-STD-810 and other standards. They’re certified for more than 100 ejected releases and 400 manual disconnects.

GORE MIL-STD-1760 Assemblies were introduced to the North Atlantic Treaty Organization (NATO) in the 1990s. Since then, they’ve delivered 100% successful store releases on many airborne platforms, including:

• A-10 Warthog
• B-1B, B-2
• F-15E, F-16, F-35
• Gripen, GR9
• S-3B Viking
• Super Lynx, Wildcat
• Tornado GR4
• Typhoon

Compared to standard umbilicals, GORE MIL-STD-1760 Assemblies are manufactured with distinct features that make them more robust in challenging aircraft pylon conditions, including:

• sealed hybrid assembly in a highly flexible design
• chemically inert, temperature-resistant, EMI shielding materials
• a variety of wire types with smaller cross-sectional diameters
• Class I & II standard versions or customized options

Our aircraft umbilical cable assembly offers system architects and engineers a host of benefits that improve their overall performance in the harshest flight conditions, like:

• guaranteed 100 ejected releases
• superior EMI protection with at least 85% optical coverage
• excellent electrical and mechanical performance in extreme conditions
• easy installation and extended operation from proven high flex life >100,000
• fully tested, qualified and certified for 500 manual disconnects
• less maintenance, downtime and replacement costs
• a variety of connectors (standard shell size 25, 17, 15 stores with relevant inserts)
• flight-proven on many airborne platforms with 100% successful store releases

These values demonstrate the mechanical and environmental performance of GORE MIL-STD-1760 Assemblies for defense aircraft.

Flight-proven on many airborne platforms with 100% successful store releases since the 1990s, we offer Class I & II standard MIL-STD-1760 breakout cable assembly versions in a variety of wire types. To meet your specific aircraft integration requirements, we also offer bespoke and custom assembly options with MIL-STD backshells, custom backshells and molding designs.

For more information or to discuss your specic application needs and place an order, contact a Gore representative today.

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