identification of aging aircraft electrical wiring group members: david bryant yuto shinagawa shaun...
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Identification of Aging Aircraft Electrical Wiring
Group Members:David Bryant
Yuto ShinagawaShaun Steinbarger
Sponsors:Dr. R. O. Stearman
Marcus Kruger
BSS Engineering Inc.
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Overview
• Background Information• Project Objectives• Experimental Setup• Problems Encountered• Laboratory Aging Results• Age Analysis Results• Recommendations• Conclusion
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Background Information• Navy and Air Force discover problem in the 1980s• Commercial aviation industry becomes concerned
– Swiss Air 111 and TWA 800– Substantial number of planes contain faulty wiring
• Aircraft industry is seeking a method to discern age of aircraft wire
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Triboelectric EffectDefinition: creation of charge imbalance due to contact
separation resulting in unwanted interference
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Triboelectric EffectSolution to the problem: relate triboelectric effect to
the age of a wire in hopes of identifying faulty wiring
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Project Objectives
• Find standards in wire aging techniques
• Design laboratory experiments• Successfully simulate wire aging• Monitor the triboelectric response
of nominal and aged wires
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Distribution of TasksProject Manager:Shaun Steinbarger
Senior Engineer:David Bryant
Senior Engineer:Yuto Shinagawa
Wire AgingChief Engineers:
David Bryant Shaun Steinbarger
1. Logistics2. Design3. Implementation
Age AnalysisChief Engineer:Yuto Shinagawa
1. Test Design2. Test Implementation3. Data Analysis
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Alpha Wire 1632• Material – rubber• 20 Gage
– 1.02 mm insulation thickness
– 3.18 mm diameter • Single Conductor• Temperature
Range– -30°C ~ 90°C
• Cost• Twisted pair
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Laboratory Aging
• CE Environmental Chambers– Heat Test– Humidity Test– Chemical Solution Test
Saltwater Jet-A fuel with Prist additive
15 specimens per test – 4 ft/specimenSpecimen removed every 3½ days
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Heat & Humidity Tests
• Temperature – 120°F
• Humidity – 70%• Temperature –
75°F
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Chemical Solution Test
• Salt Water– Salinity – 8 fl.
oz./gallon
• Jet-A Fuel
Approved 5 gallon container
Ambient temperature - 100°F
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Age Analysis I
Data Acquisition System Amplifier Shaker
Wire Circuit
Signal Analyzer
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Age Analysis II
Signal Analyzer
Amplifier
Data Acquisition System
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Age Analysis III
Wire Circuit (closed)
Electromagnetic Shaker
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Problems Encountered – Laboratory Aging
• Heat Test – Desired Temperature 170°F– Heat Lamp – Testing terminated early
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Problems Encountered II – Age Analysis
• Software Packages– Hewlett Packard 35660A– Ideas– LabView– HP3566A/67A
• Three Separate Test Runs– Closed Loop Test– Electromagnetic Interference (EMF)– Inconsistent results
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Results I – Laboratory Aging
• Humidity/Heat aging tests – No visual/physical results
• Jet-A– Expanded in diameter
and length– “Slippery” copper wire
• Salt H2O– Corrosion of copper
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Results II- Age Analysis Specimen Length of Exposure Response Amplitude
(days) (decibels)
Nominal 1 0 -79.00Nominal 2 0 -70.47Jet-A 1 3½ -57.96Jet-A 5 17½ -52.79Jet-A 10 35 -52.06Salt 1 3½ -52.90Salt 5 17½ -55.32Salt 10 35 -63.79Humidity 1 3½ -54.11Humidity 5 17½ -53.71Humidity 10 35 -55.29Heat 1 3½ -55.83Heat 5 17½ -53.65Heat 10 35 -53.90
Specimen Nominal 1 - Twisted Nominal 2 - UntwistedTest (decibels) (decibels)
1 -53.49 -62.642 -76.94 -76.753 -63.39 -52.564 -77.67 -73.095 -54.30 -67.30
• No trends in data
• Inconsistent results
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Project Objectives• Find standards in wire aging
techniques
• Design laboratory experiments
• Successfully simulate wire aging
• Monitor the triboelectric response of nominal and aged wires
Success
Success
Success
Unsuccessful
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Recommendations I• Laboratory Aging
– Reconfigure Heat Test• Locate an environmental chamber capable of 170 °F• Expose wire to extreme cycles in temperature
– Discontinue Humidity Test• Expose specimens to combinations of tests
– Cycle procedure» 1 week Jet-A» 1 week Salt H2O» 1 week Heat
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Recommendations II
• Age Analysis
– Become proficient with Ideas
– Eliminate all outside variables
– Develop more consistent testing procedures
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Conclusions• Inconsistent results
– Data does not provide any definitive trends between age and triboelectric response
– Current experimental setup does not guarantee elimination of external disturbances
• Change in scope of project– Find a relationship between the aged state of a wire and its triboelectric response– Design and evaluate experimental procedures so future groups may base their continuing research upon them
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Any Questions ???