Aging Electrical Systems Research Program Robert A. Pappas · Federal Aviation Administration...
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Aging Electrical Systems Research Program Robert A. Pappas · Federal Aviation Administration Manager, Aging Electrical Systems Research Program · AAR-480 Prepared for: EAPAS Aging Aircraft Workshop November 6, 2002
Aging Electrical Systems Research Program Robert A. Pappas · Federal Aviation Administration Manager, Aging Electrical Systems Research Program · AAR-480
Aging Electrical Systems Research Program Robert A. Pappas
Federal Aviation Administration Manager, Aging Electrical Systems
Research Program AAR-480 Prepared for: EAPAS Aging Aircraft
Workshop November 6, 2002
Slide 2
Arc Fault Circuit Breaker
Slide 3
Outline Background AFCB R&D Flight Test Program AFCB
Specification Pros/Cons of AFCB Installation AFCB Implementation
Considerations & Operational Issues Future arc fault R&D
Wrap-up / Q&A
Slide 4
Arc Fault Circuit Breaker Background
Slide 5
AFCB Purpose Mitigate the effects of electrical arcing on
aircraft wiring.
Slide 6
Background: Current Inspection Technology Current inspection
and surveillance methods for aircraft wiring are limited in
effectiveness and periodic in frequency. Arc fault circuit breakers
provide continuous monitoring & protection.
Slide 7
Background: Arc Faults Present aircraft circuit breakers are
designed to protect against over loads and short circuits. Arcing
faults draw less current than hard faults and are intermittent in
duration. Arcing faults can cause systems failures and fires.
Slide 8
Background: Typical Arcing Fault Arc Voltage and Current
Waveform of Arcing Fault at 10,000 Feet
Slide 9
Background: Wire Degradation Wiring insulation degradation
increases with time do to a variety of factors such as: Chaffing
Environmental stresses Maintenance. Degradation varies due to
design, maintenance, and operational differences
Slide 10
Background: Commercial AFCI 60 Hz AFCBs are commercially
available. Aircraft AFCBs must: Be at least 50% smaller in size.
Operate in an aircraft environment. Work in an aircraft electrical
system. Photos courtesy Eaton Corp. and Texas Instruments
AFCB Progress Two R&D contracts awarded in December 1999
Eaton Aerospace Controls Hendry Telephone Products September 2002:
Both contracts complete 20 prototype AFCBs delivered and flight
tested 115V, 400 Hz Smaller than the MS-24571 objective
Slide 14
AFCB Progress
Slide 15
Load and Power Characterization Extensive load characterization
FAA B727 (N40) Navy C-9 Boeing Power Lab Extensive power
characterization FAA B727 (N40) Boeing Power Lab Navy C-9 Nuisance
trip testing FAA B727 (N40) Boeing Power Lab
R&D Flight Test: Objectives Fly AFCBs on a variety of
aircraft and electrical loads Evaluate nuisance tripping
Demonstrate AFCB technology readiness for introduction into
civilian and military transport aircraft.
Slide 19
AFCB Installation on Navy C-9 Aircraft (VR-56) First Navy
Flight of Eaton AFCB on August 24, 2001
Slide 20
AFCB Installation on FAA B727 (N40) Eaton AFCBs Data
Recording
Slide 21
R&D Flight Test: FAA B727 Flight Test Loads NAMERATING
Oscillating Navigation Light5A DME-23A Window Lights10A Landing
Lights Left Inboard7A Passenger Cabin Ceiling Lights - Left Side
15A PROJECT POWER (60 hz converter) 15A AUX. PITOT HEAT5A WINDOW
HEAT, R4,55A
Slide 22
AFCB Results Eaton Flight Test 30.9 Flight Hours 228.2 Total
Operational Hours Hendry Flight Test 99.2 Flight Hours 793.6 Total
Operational Hours Note: Does not include Navy C-9 flight test data
or FAA ground time
Slide 23
AFCB Results Flight Test Accomplishments Several nuisance trip
modes identified, corrected, and validated. Several AFCB power
supply problems identified, corrected, and validated. Several AFCB
hardware problems identified, corrected, and validated. AFCB
Technology ready for prime time.
Slide 24
AFCB Program Status FAA has accepted and is currently
processing two STC applications for AFCB installation Limited
installation Non-critical circuits Develop operational
experience
Slide 25
AFCB Specification Development
Slide 26
Draft is nearly complete Applicable to 115V/Single Phase
devices only Broad concurrence of the AE-8B1 committee members
AE-8B General Committee Ballot SAE Council Level Ballot Get the
word out and support a YES vote on the specification ballot AE-8B1
AFCB Performance Specification
Slide 27
All current requirements for thermal circuit breaker
performance retained. Arc Fault Specific Requirements: Extensive
Rigorous Represent and address REAL conditions AE-8B1 AFCB
Performance Specification
Slide 28
Guillotine Test AE-8B1 AFCB Performance Specification
Slide 29
Guillotine Test AE-8B1 AFCB Performance Specification
Slide 30
Wet Arc Test Hot Re-Close Wet Arc Test Cold Start-Up Time Test
AE-8B1 AFCB Performance Specification
Slide 31
Loose Terminal Test AE-8B1 AFCB Performance Specification
Slide 32
Operation Inhibition (Masking) Test AE-8B1 AFCB Performance
Specification
Feedback Immunity Test AE-8B1 AFCB Performance
Specification
Slide 36
Other Arc Fault Performance Tests Arc Fault Cycling (Endurance)
Temperature (DO-160) Altitude (DO-160) EMC (DO-160) Susceptability
Radiated and Conducted Emissions Radiated Lightning Induced
Transients Electrostatic Discharge AE-8B1 AFCB Performance
Specification
Slide 37
Other Arc Fault Performance Tests (Contd) Power Quality
(DO-160) AFCB Reverse Installation no adverse safety effects AE-8B1
AFCB Performance Specification
Slide 38
AFCB Implementation Considerations and Operational Issues
Slide 39
AFCB Implementation Prevents catastrophic damage to wiring
system Reduce arc energy for starting fires Identifies circuits on
which arc faults are occurring Actively monitors circuits
Slide 40
Determining Overload vs. Arc Fault vs. Nuisance Trip Assurance
of AFCB Functionality Additional wire maintenance due to potential
increases in trip rates from interconnect system degradation Post
trip troubleshooting, determining location of arc fault AFCB
Implementation
Slide 41
Fire and Smoke Incident Data Maintenance Data Reliability Data
Risk Analysis Wiring Zones SWAMP Environmental Conditions High
Maintenance Areas Avionics bay Passenger Cabins Cargo compartments
AFCB Implementation
Joint FAA, NAVAIRSYSCOM, ONR, USAF 28VDC, 1-25A Three-phase,
5-25A MS3320 package Communication interface Remote control
Integration of 115V/400Hz AFCB and 28VDC into single breaker
Slide 45
Future AFCB R&D Contract Awards Pending Eaton Aerospace
AMETEK Schedule Year 1 Prototype Demonstration Possible Down Select
Years 2 & 3 Engineering Development, Test and Evaluation
Slide 46
AFCB Conclusions
Slide 47
Present aircraft circuit breakers are not designed to mitigate
the effects of arcing faults. 115V/Single-Phase AFCB development is
complete. Select mitigation/prevention technology appropriate to
the hazard. AFCB Conclusions
Slide 48
Wire Test & Inspection Technology
Slide 49
Excited Dielectric Test Broadband Impedance Measurement
Terahertz Reflectometry Wire Indenter Optical Chafe Detector
Validation Test Bed Pseudo-Random Binary Sequence Reflectometry
Smart Connectors Neural Network Processing of TDR/FDR Waveforms
Hi-Voltage Micro-EnergyPulsed Arrested Spark Discharge
Slide 50
Wire Degradation Research
Slide 51
Core Technical Team Raytheon Technical Services Company,
Indianapolis Brookhaven National Laboratory Lectromechanical Design
Co. (Lectromec) Sandia National Laboratory
Slide 52
Wire Degradation Research Overall Goal Model aging
characteristics of aircraft wire Establish data for predictive
techniques. Determine degradation relative to original performance
specification. Use data to develop more effective inspection
technologies
Slide 53
Wire Degradation Research Phase 1: Define Test Plan and QA
Documentation - Complete Phase 2: Testing of Aircraft Wire October
2002 - May 2004 Phase 3: Analysis and Reporting June 2004 January
2005
Slide 54
Evaluation of Performance Requirements, Test Criteria and
Procedures, for Aircraft Wire
Slide 55
Contract Award March 2002 Raytheon Technical Services Company,
Indianapolis Contract Completion March 2003 Aircraft Wire
Performance
Slide 56
Task 1 Review of Current Wire Specifications complete Task 2
Obtain Wire Performance Field Data complete Task 3
Evaluation/Assessment of Field Data vs. Performance Specifications
Task 4 Draft Minimum Wire Performance Specification Aircraft Wire
Performance
Slide 57
Evaluation of Aircraft Wiring Separation and Segregation
Requirements and Practices
Slide 58
Contract Award: September 2002 Completion: August 2003 Raytheon
Technical Services Company, Indianapolis Wiring Separation and
Segregation
Slide 59
Objectives Evaluate past and current requirements for
separation and segregation Analyze requirements relevant to service
data Identify potential improvements to requirements Explore
methods for assessing adequacy of separation/segregation of a
particular installation Wiring Separation and Segregation
Slide 60
Tasks Obtain and analyze electrical failure data relevant to
separation and segregation Identify failure modes that render the
applicable separation and segregation requirement inadequate or
otherwise reducing the effectiveness of the safety margin. Wiring
Separation and Segregation
Slide 61
Tasks Develop potential improvements Conduct tests as necessary
to investigate current requirements, support investigation and
verification of potential improvements Wiring Separation and
Segregation
Slide 62
Effects of Related & Unrelated Maintenance on the Integrity
of Aircraft Electrical Interconnect Systems
Slide 63
Contract Award: October 2002 Completion: September 2003
Raytheon Technical Services Company, Indianapolis Maintenance
Effects
Slide 64
Objectives Evaluate effects of current maintenance practices
upon the performance of the electrical interconnect system
Maintenance Effects
Slide 65
Tasks Conduct an empirical evaluation of maintenance processes
and effects. Evaluate collateral maintenance effects such as
contamination of wire bundles, and insulation blankets. Simulate
maintenance conditions to quantify maintenance effects Maintenance
Effects
Slide 66
Tasks Simulate maintenance conditions to quantify maintenance
effects on: Wire degradation Flammability Corrosion inhibiting
compounds, cleaning compounds, lubricants, etc. Debris Maintenance
Effects
Slide 67
Evaluation of Mixed Wire Types
Slide 68
Evaluation of proposals complete Award process underway Budget
- continuing resolution may delay funds availability and hence
award. Nine month duration after award Evaluation of Mixed Wire
Types
Slide 69
New Projects
Slide 70
Monitor in-service changes to wire performance and properties
5-year monitoring program/20 year life window Staggered aircraft
ages new, 5, 10, & 15 years old. In-Service Performance
Monitoring
Slide 71
Coordinate between FAA, OEM, Operator(s) Locations, parameters
of interest, instrumentation, etc. Certification by FAA In-Service
Performance Monitoring
Slide 72
Performance evaluation of aging components Connectors, splices,
etc. Switches RCCBs, Contactors, Relays, etc. Evaluation of Aging
Components
Slide 73
Exploration of advanced concepts for new and/or improved
methods of circuit protection Application of arc fault, ground
fault, and other concepts Advanced Circuit Protection