In modern aviation, power and connectivity are as critical as fuel and aerodynamics. From supplying electricity to an aircraft parked at the gate to powering ground support equipment (GSE) on the apron, robust and purpose-built power solutions ensure safety, efficiency, and reliability in some of the most demanding operating environments in the world.
This article explores the main types of power equipment and electrical connectors used in the aviation sector, explaining how they work, where they are used, and why each solution is uniquely suited to its specific task.
The Demands of Power in Aviation Environments
Aviation power systems must meet a set of challenges that few other industries face:
- High reliability requirements – failures can disrupt operations or compromise safety
- Harsh operating conditions – vibration, temperature extremes, moisture, and contaminants
- Strict safety standards – prevention of arcing, overheating, and incorrect connections
- Mobility and flexibility – equipment must be easily deployed on ramps and in hangars
- Compatibility – aircraft from different manufacturers must connect seamlessly to ground systems
To meet these needs, aviation relies on specialised power equipment and connector designs rather than general industrial solutions.
Aircraft Ground Power Systems
Ground Power Units (GPUs)
Ground Power Units provide electrical power to an aircraft while it is on the ground, allowing systems such as avionics, cabin lighting, air conditioning, and onboard computers to operate without running the aircraft’s auxiliary power unit (APU).
Forms of GPUs include:
- Fixed GPUs – installed at gates or hangars
- Mobile GPUs – diesel, petrol, or electric-powered towable units
- Solid-state GPUs – using advanced electronics to provide clean, stable power
Why GPUs are suited to aviation:
- Deliver precise voltage and frequency required by aircraft systems
- Reduce fuel consumption, emissions, and noise compared to APUs
- Designed with redundancy and protection against voltage spikes
Aircraft Power Standards
Most commercial aircraft use 115/200V AC at 400Hz, while some smaller aircraft and helicopters use 28V DC systems.
- 400Hz AC allows smaller, lighter motors and transformers—ideal for aircraft weight reduction
- 28V DC systems are simpler and common in light aviation and military applications
Ground equipment is engineered to match these exact specifications, preventing damage to sensitive onboard electronics.
Aviation-Specific Power Connectors
Aircraft Ground Power Connectors
Aircraft ground power connectors are highly specialised, rugged connectors designed to ensure safe and foolproof connections.
Key characteristics:
- Multi-pin designs with precise alignment
- Locking mechanisms to prevent accidental disconnection
- Heavy-duty insulation to handle high currents
- Weather-resistant construction
Why they are aviation-specific:
- Prevent incorrect phase connections
- Ensure grounding before live power is applied
- Operate reliably in rain, heat, cold, and vibration
The connectors used with aircraft ground power supply equipment are typically colour-coded and standardised to ensure compatibility across fleets and airports.
DC Power Connectors (28V Systems)
For aircraft using DC systems, connectors are optimised for:
- High current transfer
- Minimal voltage drop
- Rapid connection and disconnection during servicing
They are commonly used during maintenance, avionics testing, and engine start assistance.
Power Solutions for Ground Support Equipment (GSE)
Ground support equipment includes everything from belt loaders and baggage tractors to aircraft tugs and catering trucks. Each has its own power requirements.
Battery-Electric GSE
Electric GSE is increasingly popular due to sustainability goals and operational efficiency.
Power equipment includes:
- High-capacity lithium-ion or lead-acid batteries
- Onboard chargers
- External charging connectors
Why electric power suits GSE:
- Zero emissions on the ramp
- Lower noise levels
- Reduced maintenance compared to internal combustion engines
Charging Connectors for Electric GSE
Charging connectors for GSE are designed to handle:
- High currents for rapid charging
- Frequent connection cycles
- Outdoor exposure
They often feature:
- Keyed designs to prevent incorrect voltage connection
- Sealed housings for moisture and dust protection
- Durable contacts to minimise wear
AC Industrial Connectors (Aviation-Adapted)
Some GSE uses industrial-style AC connectors adapted for aviation environments.
Typical features include:
- High ingress protection (IP-rated) housings
- Robust strain relief
- Colour coding for voltage identification
These connectors are ideal for equipment such as:
- Hangar tools
- Ground air conditioning units
- Maintenance support systems
Power Distribution and Safety Equipment
Power Distribution Units (PDUs)
PDUs are used to manage and distribute power safely across multiple systems.
Why PDUs are essential:
- Protect equipment from overloads
- Enable controlled startup and shutdown
- Provide monitoring and fault detection
In aviation, PDUs are often mobile or rack-mounted with aviation-rated connectors.
Cable Assemblies and Power Leads
Aviation power cables are engineered differently from standard industrial cables.
Key design elements:
- Extra-flexible conductors to resist fatigue
- Abrasion-resistant outer jackets
- Shielding to minimise electromagnetic interference
These cables must withstand constant dragging across concrete, exposure to jet fuel, and extreme temperatures.
Connectivity Beyond Power: Data and Control Interfaces
Modern aviation increasingly integrates data connectivity alongside power.
Examples include:
- Combined power and data connectors
- CAN bus and Ethernet connections for GSE diagnostics
- Control cables for automated docking and charging systems
These hybrid solutions reduce cable clutter and improve operational efficiency while maintaining strict safety separation between power and data circuits.
Why Specialised Aviation Power Solutions Matter
Using generic connectors or power equipment in aviation environments introduces risks:
- Incorrect voltage or frequency
- Loose or unreliable connections
- Increased wear and failure rates
- Safety hazards to personnel and aircraft
Aviation-specific power and connectivity solutions are engineered to eliminate these risks, ensuring compliance with international aviation standards and delivering dependable performance under constant operational pressure.
Conclusion
Power and connectivity solutions form the backbone of both aircraft ground operations and ground support equipment performance. From precision-engineered ground power units to rugged aviation connectors and high-capacity electric GSE charging systems, every component is designed with a singular focus: safety, reliability, and efficiency in demanding environments.
As aviation continues to evolve—particularly with the growth of electric ground equipment and smarter airport infrastructure—the importance of specialised power and connectivity solutions will only increase, supporting smoother operations and a more sustainable future for the industry.