Electrical Harnessing in Satellite Launch Vehicles of ISRO Methods for Sustainable, Safe and Reliable Systems Vikram Sarabhai Space Centre

Format:

Book

Conference/Event

Author/Creator:

K S, Nithish, author.

TR, Binny, author.

D S, Praveen Kumar, author.

Conference Name:

AeroCON 2026 (2026-06-04 : Bangalore, India)

Language:

English

Subjects (All):

Reusable launch vehicles and shuttles.

Launch vehicles.

Connectors and terminals.

Lean manufacturing.

Cadmium.

Local Subjects:

Reusable launch vehicles and shuttles.

Launch vehicles.

Connectors and terminals.

Lean manufacturing.

Cadmium.

Physical Description:

1 online resource

Place of Publication:

Warrendale, PA SAE International 2026

Summary:

The electrical harness system of satellite launch vehicles functions as the backbone of spacecraft avionics; inter connecting subsystems through complex networks of wires and connectors. An electrical harness is a group of wires bunched together and terminated in connectors. The common insulations used for launch vehicle applications include PTFE, Polyimide, ETFE and TKT. The connectors used are of aerospace grade and connectors tailored for space applications. With over 5000 connectors and 200 km of cables constituting nearly 20% of vehicle mass, the design, fabrication, and sustainability of these systems are critical. The insulations of connectors inserts or the wires are critical for the durability of harness elements. Nevertheless, these insulations are non-expendable and pose disposal challenges and some releases toxic gases when burned or due to vacuum outgassing phenomenon. Also, the cadmium plating which is often used for the environmental resistance of connector shells presents additional risks to the working humans due to its carcinogenic nature and shows tendency to bloom out during storage. This paper presents the methodologies and innovations implemented to develop safe, reliable, and environmentally sustainable harness systems for current and future launch vehicles. Key advancements include the adoption of lean manufacturing practices for waste reduction, the replacement of hazardous cadmium-plated connector shells with stainless-steel alternatives, and the induction of TKT-insulated wires to prevent arc tracking and ensure human-rating compatibility. Additionally, lightweight composite connectors and micro-miniature interconnects are being qualified to support mass optimization in reusable launch vehicles. Through these strategic measures, the study demonstrates how the integration of sustainable materials, safety-oriented design, and process optimization can enhance the performance, safety, and environmental footprint of launch vehicle electrical harness systems

Notes:

Vendor supplied data

Access Restriction:

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