High Voltage Quick-Disconnect Harness System for Helmet-Mounted Displays

We have developed a pilot's harness-mounted, high-voltage quick-disconnect connector for a binocular, helmet-mounted display system. It connects and disconnects with power off, and disconnects “hot” without pilot intervention, external sparks, or exposed hot embers in the explosive environment of the cockpit. Furthermore, we have successfully implemented a procedure in which high-voltage pins of up to 13.5 kV disconnect inside a hermetically sealed unit before the physical separation of the connector. The locations of the conductors and shields are designed to avoid crosstalk among adjacent circuits. The connector shell is equipped to house and cool two hybrid video amplifiers that provide up to 70 MHz video bandwidth to the helmet-mounted CRTs. The connector has been human-engineered to facilitate the arm, head, and torso movements of the pilot. Shielded cables and wires are potted as a multilayered ribbon for maximum flexibility between the connector and helmet. Stiff cabling is routed between the connector and the aircraft panel to avoid dangling cables during seat ejection. The system has been successfully tested for specifications, performance, and safety factors.