STAFF Update: New Mast Head Interface for Highly Dynamic Mobile Applications
- Aug 3
- 3 min read
As part of our internal development program STAFF – Stability for Future, we continuously enhance the ZIPPERMAST to meet future operational requirements. A current milestone is the further development of the mast head interface – the connection between the mast and the payload, such as sensors, communication systems or effectors.
New Requirements in Mobile Defence Applications
With the increasing integration of the ZIPPERMAST on mobile platforms, the requirements for mechanical robustness are also increasing. Highly dynamic operational profiles on mobile platforms, such as tracked vehicles and unmanned ground vehicles (UGVs) exposed to challenging terrain conditions, represent a particular challenge. These applications generate shock and vibration loads as well as tilting moments that impose specific requirements on the mechanical interface.
To address these demanding operational scenarios, we have specifically enhanced the mast head interface.
Continuous Improvement Through Iterative Development
The evolution of the mast head interface was achieved through several development stages. The starting point was a proven design with separate guiding, centering and clamping elements, which has demonstrated reliable performance across numerous applications. As requirements for highly dynamic mobile applications increased, the interface was systematically optimized to meet these new challenges.
In the first step, the existing design was enhanced with an additional end-stop function to further improve the absorption of occurring loads. However, investigations of this intermediate solution showed that complete load transfer could only be achieved to a limited extent due to geometric constraints.
These findings were directly incorporated into the next development stage. The current design therefore follows a fundamentally optimized approach: an integrated 60° conical geometry combined with a triangular interface block provides centering and load transfer through a form-fit connection between mast and payload.
This results in a self-centering connection with optimized load distribution, specifically designed for highly dynamic applications with increased lateral forces and tilting moments.
Advantages of the New Conical Interface
The new geometry provides several key advantages:
Self-centering: The payload automatically aligns to the correct position during installation.
Optimized load transfer: Lateral forces and tilting moments are transferred into the structure through the form-fit conical geometry over a large contact area.
Increased shear load capacity: The circumferential collar enhances the capability of the interface to withstand high lateral loads.
Integrated anti-rotation feature: The triangular interface prevents payload rotation without requiring additional components.
Reduced number of separate components: Functions such as guidance and load transfer are integrated into the geometry, reducing mechanical complexity and additional interfaces.
Beyond the mechanical improvements, the new geometry provides additional operational benefits:
Reduced visual signature: The mounting ring conceals the sensor and LED of the end-stop detection system.
Improved protection against dirt and dust: The enclosed design provides additional protection for the connection area in mobile operating environments.
Development Process with Laboratory Validation
The further development of the mast head interface is part of our continuous STAFF program. We follow an iterative development approach in which findings from design and engineering work, simulations, internal load analyses and practical testing are continuously incorporated into the optimization of the components.
This process is complemented by laboratory testing according to IEC 60068-2-80 and NATO AECTP-400 – test procedures established for evaluating mechanical loads in military applications and used in a comparable environment to MIL-STD-810H.
The new conical connection will be used in particular for applications with the highest dynamic requirements.
With STAFF, our goal is to continuously adapt the ZIPPERMAST to future operational scenarios – delivering even greater robustness, reliability and operational capability under the most demanding conditions.
