Identification of Aging Aircraft Electrical WiringMidterm ReportAbstractAcknowledgementsList of Tables and Figures1.0 Introduction1.1 History of the Problem1.2 Solutions to the Problem1.3 Laboratory Aging Setup1.4 Age Analysis1.5 Report Overview2.0 Technical Background2.1 Types of Wire Failures2.2 Current Methods Used to Detect Faulty Wiring3.0 Theory3.1 Triboelectric Effect3.2 Frequency Response4.0 Laboratory Specimen4.1 Wire Selection4.2 Initial Setup of the Wire Specimen5.0 Laboratory Aging5.1 Heat Test5.2 Humidity Test5.3 Chemical Tests5.3.1 Salt-Water Solution5.3.2 Jet-A Fuel5.4 Desired Outcome5.5 Preliminary Aging Effects6.0 Age Analysis6.1 Experimental Setup6.1.1 Signal Analyzer6.1.2 Amplifier6.1.3 Shaker6.1.4 Chessboard6.2 Preliminary Results6.3 Quantitative Comparisons6.4 Consistency of Results6.5 Anticipated Results6.6 Inherent Difficulties7.0 Work to be Completed8.0 Task Distributions9.0 Cost Analysis10.0 Conclusion11.0 Works Cited12.0 Appendix - TimelineIdentification of Aging Aircraft Electrical Wiring BSS Engineering Inc. Midterm Report Group Members: Shaun Steinbarger – Project Manager David Bryant – Senior Engineer Yuto Shinagawa – Senior Engineer Sponsors: Dr. R. O. Stearman Marcus Scott Kruger October 18, 2002BSS Engineering, Inc. Austin, TX 78705 October 18, 2002 Dr. R.O. Stearman Department of Aerospace Engineering and Engineering Mechanics College of Engineering Dear Sir: The attached report contains a comprehensive analysis of the wire aging experiments conducted by BSS. Included within the report is background information, experimental setup, and initial findings. The background information discusses the problem at hand, presents some landmark aircraft failures, and contains a recommended solution to the problem. In the experimental setup portion, BSS depicts fundamental techniques associated with laboratory aging and the wire age analysis process. Finally, BSS will present our initial findings from one week of aging and testing. We will also provide insight into our future plans and objectives. Future work includes continuing to age and test the wire specimens. After all the wires have completed the aging process, BSS will chart any correlation between the numbers of days the wire was aged and the increase/decrease in the triboelectric effect. The attached report contains all work to date; however, if you have any questions/comments, please feel free to contact our office at (512) 413-2829 or via email [email protected]. Sincerely, David Bryant Shaun Steinbarger Senior Engineer Project Manager Yuto Shinagawa Senior Engineer iAbstract Laboratory aging tests and age analyses were conducted on 4 ft specimens of Alpha Wire 1632, a single conducting, rubber insulated, copper wire. The laboratory aging tests required the use of a controlled environment. These aging tests were accomplished with the use of three environmental chambers located in the Civil Engineering Department at the University of Texas at Austin. Wires exposed to heat, humidity, and two chemical solution tests (salt-water and Jet-A fuel) were housed within these chambers. The tests were conducted in hopes of successfully simulating the aging of electrical wiring within aircraft. Every 3.5 days, an aged specimen was removed and then analyzed the following day. The analysis, the second phase of the project, consisted of sending a charge through the wire in order to monitor the triboelectric effect. The triboelectric effect between the nominal and aged wires was then compared to determine whether our initial hypothesis – the triboelectric response varies with the age and quality of the wire – was correct. Preliminary results show that the first phase of the project, simulating wire aging, has been a success. Visual inspection has revealed that the wire submerged in Jet-A fuel has displayed characteristics of an aged wire. This deterioration was also verified by comparing amplitude plots between the nominal and aged specimens, illustrating the difference in the triboelectric effect. As a result of these initial findings, it has been concluded that the triboelectric is an efficient method for detecting aging aviation wiring. iiAcknowledgements First, BSS would like to thank our sponsors for this project, Dr. R.O. Stearman and Marcus Kruger. Dr. Stearman, a professor of aerospace engineering at the University of Texas at Austin, has overseen this project. He has been instrumental in acquiring individual components for this project. These components include Jet-A fuel, two containers that housed the chemical solvents, three environmental chambers, and age analysis equipment. Marcus Kruger, an aerospace graduate student, provided his knowledge and guidance during the setup and execution of the project. His knowledge was apparent during weekly consultation sessions, in which he helped develop the experimental setup and the methods for analyzing the specimens. Finally, BSS would like to thank those individual persons and corporations who devoted either their time or their materials for the project. Personnel include Ronald Galvez, Engineering Directorate at NASA JSC; Frank Wise, onsite electrician for the Aerospace Department; Gonzalo Zapato, Lab/Tech Service Supervisor for the Civil Engineering Department; Irezama Anderson, Safety Specialist; Rick Maldonado, Tech Staff Assistant; Javier Fuentealba, aerospace engineering graduate student; and Signature Flight Support, located at Austin Bergstrom International Airport. Without these individual contributions, the experiments conducted by BSS would have been incredibly difficult and time consuming. iiiTable of Contents Listof Tables and Figures................................................................................................... vi 1.0 Introduction................................................................................................................... 1 1.1 History of the Problem.............................................................................................. 1 1.2 Solutions to the Problem........................................................................................... 2 1.3 Laboratory Aging Setup............................................................................................ 2 1.4 Age