Identification of Aging Aircraft Electrical WiringOverviewBackground InformationTriboelectric EffectSlide 5Project ObjectivesDistribution of TasksAlpha Wire 1632Laboratory AgingHeat & Humidity TestsChemical Solution TestAge Analysis IAge Analysis IIAge Analysis IIIProblems Encountered – Laboratory AgingProblems Encountered II – Age AnalysisResults I – Laboratory AgingResults II- Age AnalysisSlide 19Recommendations IRecommendations IIConclusionsAny Questions ???Identification of Aging Aircraft Electrical WiringGroup Members:David BryantYuto ShinagawaShaun SteinbargerSponsors:Dr. R. O. StearmanMarcus KrugerBSS Engineering Inc.Overview•Background Information•Project Objectives•Experimental Setup•Problems Encountered•Laboratory Aging Results•Age Analysis Results•Recommendations•ConclusionBackground 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 wireTriboelectric EffectDefinition: creation of charge imbalance due to contact separation resulting in unwanted interferenceTriboelectric EffectSolution to the problem: relate triboelectric effect to the age of a wire in hopes of identifying faulty wiringProject Objectives•Find standards in wire aging techniques•Design laboratory experiments•Successfully simulate wire aging•Monitor the triboelectric response of nominal and aged wiresDistribution of TasksProject Manager:Shaun SteinbargerSenior Engineer:David BryantSenior Engineer:Yuto ShinagawaWire AgingChief Engineers: David Bryant Shaun Steinbarger1. Logistics2. Design3. ImplementationAge AnalysisChief Engineer:Yuto Shinagawa1. Test Design2. Test Implementation3. Data AnalysisAlpha 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 pairLaboratory Aging•CE Environmental Chambers–Heat Test–Humidity Test–Chemical Solution TestSaltwaterJet-A fuel with Prist additive15 specimens per test – 4 ft/specimenSpecimen removed every 3½ daysHeat & Humidity Tests•Temperature – 120°F •Humidity – 70%•Temperature – 75°FChemical Solution Test•Salt Water–Salinity – 8 fl. oz./gallon•Jet-A FuelApproved 5 gallon containerAmbient temperature - 100°FAge Analysis IData Acquisition SystemAmplifier ShakerWire CircuitSignal AnalyzerAge Analysis IISignal AnalyzerAmplifierData Acquisition SystemAge Analysis IIIWire Circuit (closed)Electromagnetic ShakerProblems Encountered – Laboratory Aging•Heat Test –Desired Temperature 170°F–Heat Lamp –Testing terminated earlyProblems Encountered II – Age Analysis•Software Packages–Hewlett Packard 35660A–Ideas–LabView–HP3566A/67A•Three Separate Test Runs–Closed Loop Test–Electromagnetic Interference (EMF)–Inconsistent resultsResults 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 copperResults 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 -53.90Specimen 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 resultsProject 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 UnsuccessfulRecommendations 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 HeatRecommendations II•Age Analysis–Become proficient with Ideas–Eliminate all outside variables–Develop more consistent testing proceduresConclusions•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 themAny Questions