Software-Defined Combat Vehicles Connector Technology as a Key Factor in the Modernisation of Ground Vehicles

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Modern ground combat vehicles have evolved from single-purpose devices with fixed hardware to software-defined, expandable systems. Such flexibility requires robust, highly reliable connector technologies.

Those connectors should be able withstand multiple upgrades without requiring complete redesigns of wiring harnesses or structural components. Sean Fitall, European Product Manager at connector specialist PEI-Genesis, considers in this article the role of scalable connectors in the next generation of military ground vehicles. 

Among the most widely used solutions supporting this transformation are connectors that comply with the MIL DTL 38999 specification. These circular connectors, which have proven themselves over decades in military applications and in aerospace, are particularly valued for their high-density contact arrangement, robust construction and flexibility in transmitting signals, data and power in a single interface.

These connectors are compatible with open standards such as VICTORY, NATO Generic Vehicle Architecture (GVA) and Modular Open Systems Approach (MOSA), which support interoperable, expandable systems via standardised interfaces.

By using uniform connector geometries, contact layouts and coupling mechanisms, system integrators can reduce the complexity of vehicle wiring harnesses and more easily integrate new mission systems from different suppliers.

Power Supply for Electrified Platforms

As open architectures become more prevalent, vehicle electrical systems must not only transmit signals and data, but also meet the high-voltage and high-current requirements of battery electric drives, traction inverters and energy-intensive subsystems. Conventional low-current connectors are often inadequate due to their limitations in terms of current capacity, heat dissipation and sealing performance.

To overcome these challenges, high-performance variants based on the MIL DTL 38999 form factor have been developed. With advanced contact technologies such as Amphenol's Radsok, these connectors can support up to 1000 A, depending on the configuration, while maintaining the sealing, vibration resistance and mating strength of their signal-capable counterparts. This allows designers to standardise the interfaces for power and signals across the entire platform.

Such standardisation simplifies integration, supports distributed power architectures and helps reduce system weight by allowing power components to be positioned closer to loads. Many variants also offer integrated voltage and temperature measurement, enabling predictive maintenance and improved fault diagnosis.

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Designed for Combat Use

As a vehicle's digital infrastructure becomes increasingly important to the success of its missions, the seamless integration of new subsystems is also critical. LiDAR, EO/IR cameras, radar and AI support require high-speed, low-latency connections that can operate reliably in demanding electromagnetic environments. MIL-DTL-38999 connectors are well suited for this task, offering coax, twinax, quadrax and fibre optic contacts in a single-shell housing with robust EMI shielding.

Their effective shielding and mechanical resilience make them ideal for transmitting real-time data in an environment with high-performance systems, in-vehicle interference devices and severe vibration. By supporting high-bandwidth sensor fusion and AI-driven situational awareness tools, these connectors enable advanced combat capabilities without compromising system integrity.

Plug-and-fight Capabilities

Given increasing system complexity and growing mission requirements, platform flexibility has become a key design priority. Modern doctrine demands vehicle platforms that can be quickly reconfigured for different mission requirements.

For example, a vehicle may support electronic warfare operations one day and the next day it may need to transport a drone defence system or provide advanced communications systems. To ensure this level of flexibility, standardisation of signal and power interfaces is required. When platforms use the same MIL-DTL-38999 connector configurations for different payload types, mission kits can be quickly added, removed or exchanged without having to rewire or modify the base infrastructure.

This enables true plug-and-fight capabilities, allowing teams to reconfigure their platforms in the field without delays or high workshop costs. Power-carrying variants of these connectors ensure that even power-hungry payloads such as radar arrays or directed energy systems are supported safely and reliably. This not only simplifies integration, but also improves adaptability, operational readiness and speed of deployment in various combat situations.

Scalable Solutions for Long-Term Operational Readiness

To ensure long-term platform flexibility, connector systems are needed that can support frequent technical upgrades without requiring a redesign of the vehicle's core infrastructure. While military vehicles often remain in service for decades, on-board electronics typically evolve in much shorter cycles.

To bridge this gap, the connector infrastructure must be scalable, standardised and robust so that new technologies can be integrated without compromising physical or electrical integrity. Systems based on MIL-DTL-38999 offer this stability and therefore provide a reliable foundation for future capabilities.

Whether integrating AI-enabled edge computing, advanced sensors or electrified drive systems, these connectors ensure that platforms remain compatible, reconfigurable and resilient, supporting the evolution towards open, modular and software-defined vehicles. An example of this scalability in practice is the Amphenol Rhino series, a high-performance connector solution based on the MIL-DTL-38999 mechanical platform.

The series was developed to meet the requirements of modern military systems and combines the robust design of Series III housings with Radsok heavy-duty contacts. This means that currents of up to 1000 A can be handled in a sealed, touch-safe housing, making the connectors particularly suitable for electrified propulsion systems, high-power subsystems and modular payloads.

To support the provision of these scalable solutions, PEI-Genesis offers extensive inventory, in-house technical expertise and rapid assembly services. This means fast delivery of customised Rhino assemblies, allowing integrators to shorten their lead times and respond quickly to changing system requirements, even late in the development cycle.

As modern ground vehicles become increasingly modular, electrified, and digitally connected, the importance of connector technology is greater than ever before. Whether you're managing high-speed data from advanced sensors or distributing high-voltage power to hybrid drives, scalable connectors based on the MIL-DTL-38999 standard offer the durability, flexibility and interoperability that modern military platforms require.

For more information on military specification connectors available from PEI-Genesis, visit www.peigenesis.com.