1. Identification of Aging Aircraft Electrical Wiring Group Members: David Bryant Yuto Shinagawa Shaun Steinbarger Sponsors: Dr. R. O. Stearman Marcus Kruger BSS Engineering Inc.

2. Overview Background Information Project Objectives Experimental Setup Problems Encountered Laboratory Aging Results Age Analysis Results Recommendations Conclusion

3. 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

4. Triboelectric Effect Definition: creation of charge imbalance due to contact separation resulting in unwanted interference

5. Triboelectric Effect Solution to the problem: relate triboelectric effect to the age of a wire in hopes of identifying faulty wiring

6. Project Objectives Find standards in wire aging techniques Design laboratory experiments Successfully simulate wire aging Monitor the triboelectric response of nominal and aged wires

7. Distribution of Tasks Project Manager: Shaun Steinbarger Senior Engineer: David Bryant Senior Engineer: Yuto Shinagawa Wire Aging Chief Engineers: David Bryant Shaun Steinbarger 1. Logistics 2. Design 3. Implementation Age Analysis Chief Engineer: Yuto Shinagawa 1. Test Design 2. Test Implementation 3. Data Analysis

8. 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

9. 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/specimen  Specimen removed every 3½ days

10. Heat & Humidity Tests Temperature – 120°F Humidity – 70% Temperature – 75°F

11. Chemical Solution Test Salt Water –Salinity – 8 fl. oz./gallon Jet-A Fuel  Approved 5 gallon container  Ambient temperature - 100°F

12. Age Analysis I Data Acquisition System AmplifierShaker Wire Circuit Signal Analyzer

13. Age Analysis II Signal Analyzer Amplifier Data Acquisition System

14. Age Analysis III Wire Circuit (closed) Electromagnetic Shaker

15. Problems Encountered – Laboratory Aging Heat Test –Desired Temperature 170°F –Heat Lamp –Testing terminated early

16. 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

17. Results I – Laboratory Aging Humidity/Heat aging tests –No visual/physical results Jet-A –Expanded in diameter and length –“Slippery” copper wire Salt H 2 O –Corrosion of copper

18. Results II- Age Analysis No trends in data Inconsistent results

19. 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  Unsuccessful

20. 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 H 2 O »1 week Heat

21. Recommendations II Age Analysis –Become proficient with Ideas –Eliminate all outside variables –Develop more consistent testing procedures

22. 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

23. Any Questions ???