High-Current Probes in Aerospace High-Current Systems

Time：2025-07-11 Views：1 source:

　　In aerospace applications, high-current probes are integral to testing and monitoring power systems in aircraft, satellites, and spacecraft, where currents can exceed 1000A in systems like electric propulsion, landing gear actuators, and avionics. These probes must operate reliably in extreme environments, including wide temperature ranges (-55°C to 125°C), high vibration, and low pressure.

　　Material selection is critical for aerospace high-current probes. Contact surfaces are often plated with gold or silver to minimize oxidation and ensure low contact resistance, even after prolonged exposure to harsh conditions. The core conductors may use high-purity copper or copper alloys with high tensile strength to withstand mechanical stress during launch or flight. Insulation materials such as PEEK or Teflon provide excellent dielectric properties and resistance to aviation fluids (e.g., hydraulic oils, fuels).

　　Design features focus on miniaturization and weight reduction to meet aerospace constraints. Probes are compact, with integrated cooling mechanisms (e.g., heat sinks or air channels) to dissipate heat generated by high currents. They may also include ruggedized connectors (e.g., MIL-DTL-38999) to ensure secure connections in high-vibration environments. Accuracy is paramount for aerospace testing, with probes achieving measurement errors of less than ±0.1% across their current range. Additionally, they often feature hermetic sealing to prevent moisture or debris ingress, critical for maintaining performance in space or high-altitude environments. Compliance with standards like SAE AS4373 ensures these probes meet the stringent reliability and safety requirements of aerospace applications.