Ruggedized Communication Systems: When Flames Come Out of the Power Switch (And How We Fixed It)
How Radio Design Group's 30+ years of experience turned a spectacular EMP test failure into mission-critical success for DoD applications
It’s rare to see product development go so smoothly that every test is successful. In fact, the whole point of testing new concepts and products is to find the weak points so that the final item exceeds requirements. Every failed test, every "let the smoke out" moment, and yes, even when flames shoot out of power switches, these experiences become the foundation for bulletproof final designs.
At Radio Design Group, we've had our share of spectacular failures over three decades of RF engineering. Battery fires, circuit meltdowns, and countless subtle failures that only reveal themselves under the most demanding conditions. But it's these stumbling blocks that have made us experts in ruggedized communication systems for the most challenging environments on Earth.
The DoD Alerting System That Caught Fire (Literally)
One failure stands out that perfectly illustrates why EMP-resistant communication systems require more than theoretical engineering—they demand real-world testing and the experience to turn failures into victories.
We were developing a wireless alerting system in partnership with a principal defense contractor for strategic aircrew applications. The system had two main components: a portable pager-like receiver and a fixed receiver designed for pilot-ready rooms, complete with an attention-grabbing Klaxon horn.
The critical requirement? Electromagnetic pulse (EMP) resistance—specifically, high-altitude EMP (HEMP) protection.
The Challenge: Power Lines as Giant EMP Antennas
Making the portable pager EMP-resistant was straightforward for our team. We passed those tests with our own engineering expertise. The Klaxon, however, presented a unique challenge.
Here's what makes mains-powered equipment especially vulnerable: power lines act like massive antennas during an EMP event, collecting and channeling destructive energy directly into connected devices. It's a problem that requires specialized engineering for power line EMP protection.
Fortunately, our defense contractor partner had extensive experience with power line EMP issues. They handled the power supply design while we focused on the radio frequency communications section.
Test Day: Everything Perfect Except...
When test day arrived, we were confident. Multiple system components, rigorous testing protocols, everything performing exactly as designed.
Almost everything.
I heard back from the EMP specialist at the test site. "Everything on the Klaxon went fine, except that flames came out of the power switch."
Flames?!
That didn't sound "fine" to me, but the specialist calmly explained this was a correctable failure. He was right. A different power switch specification and slight modifications to the power line circuitry solved the problem completely. The revised Klaxon passed EMP testing with flying colors.
To this day, when we discuss near-perfect test results with challenging edge cases, someone inevitably mentions "but flames came out of the power switch."
Why Ruggedized Communication Systems Demand Real-World Experience
This experience illustrates why specialized communication systems for defense and critical applications require more than standard engineering approaches. When your equipment must function in environments with:
EMP and HEMP threats
Severe jamming (both incidental and intentional interference)
Low probability of intercept requirements
Extreme environmental conditions
Bandwidth restrictions and noise challenges
...you need engineers who've literally seen the smoke, handled the flames, and know how to turn failures into mission-critical successes.
RDG's Ruggedized Communication Systems Capabilities
Our customized equipment design and manufacturing for specialized communications includes:
EMP/HEMP Protection: Three decades of experience with electromagnetic pulse resistance, including the power line vulnerabilities that catch many designs off-guard.
Anti-Jamming Technology: Systems designed to maintain communication integrity despite severe intentional and incidental interference.
Low Probability of Intercept (LPI): Encrypted systems that keep communications secure in contested environments.
Bandwidth-Restricted Voice Systems: Crystal-clear communication even within extremely narrow frequency allocations.
High Noise Tolerance: Equipment that maintains performance in acoustically and electromagnetically challenging environments.
Environmental Ruggedization: Waterproof, shock-resistant, and temperature-extreme capable systems for field deployment.
From Concept Validation to Mission-Ready Systems
Whether you're developing alerting systems for difficult environments, portable field communications, or fixed installation equipment for defense applications, RDG brings proven expertise to every challenge.
Looking to validate your RF engineering concept? Learn more about our invention validation process.
Ready to discuss your specialized communication requirements? Skip the automated responses and chat with a real person. We're here for every step from initial concept through manufacturing and deployment.
DoD Technology Lifecycle Support
Mission-critical technology ages, but replacement budgets don't always keep pace. Our comprehensive DoD obsolescence mitigation services help extend the operational lifespan of RF technology, keeping vessels and systems mission-ready when it matters most.
Radio Design Group: Where 30+ years of RF engineering experience meets the real-world challenges of specialized communication systems. Sometimes there are flames. We always find the solution.
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