The topics are presented in viewgraph form and include the following: wiring systems, quality control, qualification and standardization, and maintenance costs

Meiner, Thomas

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ORGANIZEDWIRINGSYSTEMS
ThomasMeiner
NavalAir WarfareCenter
Indianapolis,Indiana
N94- 28705
SUMMARY
THE WIRING SYSTEM IS THE LINK FOR ALL
AND MUST BE INCLUDED IN THE QUALITY
ASSURANCE PROGRAM.
SYSTEMS,
WITHOUT QUALIFICATION AND STANDARDIZATION,
WIRING MAINTENANCE COSTS WOULD BE
EXORBITANT.
NAVY STUDIES SHOW THAT WIRING (TAKEN COLLECTIVELY)
IS CONSISTENTLY ONE OF THE TOP FIVE "BAD ACTOR"
SYSTEMS OF EVERY AIRCRAFT TYPE FOR:
- NON-MISSION CAPABLE (NMC)
- PARTIAL MISSION CAPABLE (PMC)
- MAINTENANCE MAN HOURS (M/MHRS)
PIm(_il)_l_ PAGE BLANK NOT FK.MED 63
https://ntrs.nasa.gov/search.jsp?R=19940024202 2020-06-16T15:21:56+00:00Z
TRADITIONAL HARNESSING PITFALLS
• EXPENSIVE AND DIFFICULT TO MANUFACTURE,
• NORMALLY INSTALLED PARTIALLY ASSEMBLED,
• DIFFICULT TO MAINTAIN AND MODIFY,
• REQUIRES TWISTED AND SHIELDED COMPONENTS TO
CONTROL EMI,
• SIZE AND WEIGHT REDUCTION LIMITED BY MECHANICAL
AND ELECTRICAL FACTORS,
• REQUIRES HIGH-COST TRAINING AND PIECE-PARTS
LOGISTICS THAT IS OFTEN INEFFECTIVE, AND
• ALL MAINTENANCE IS "0" OR "D"
ORGANIZED WIRING: "WIRING WITH FIXED RELATIVE
POSITIONING OF CIRCUITS. THIS IS TYPICALLY A
RECTANGULAR BUNDLE."
ORGANIZED
WIRING SYSTEMS
Y
ROI 12S
64
TYPICAL HARNESS CROSS SECTIONS
CONVENTIONAL HARNESS
_v----- REG. WIRE
SHIELDED WIRE
SHIELDED
TWISTED PAIR
ROI HARNESS ALL WIRES
UNSHIELDED
OWS IS APPLICABLE TO:
• NEW DESIGN,
• REWORK,
• ECP'S, AND
• ALSO APPLIES TO MISSILES, STORES, PODS, SUSPENSION
EQUIPMENT, AND AVIONIC'S SUITES
65
ADVANTAGES
• WEIGHT SAVINGS
• IMPROVED RELIABILITY
• PREDICTABLE EMI PERFORMANCE
• IMPROVED MAINTAINABILITY
• LIFE CYCLE COST SAVINGS
• ACTIVE WIRING FEATURES
RIBBON HARNESSES REDUCE WEIGHT BY:
• ELIMINATION OF INDIVIDUAL SHIELDS AND JACKETS,
• LESS OUTER BRAID PER UNIT HARNESS LENGTH,
• ELIMINATION OF SHIELD - TERMINATORS AND EMI
BACKSHELLS,
• DOWN-GUAGING OF WIRES DUE TO IMPROVED MECHANICAL
AND ELECTRICAL CHARACTERISTICS OR RIBBONS, AND
• REPLACING HEAVY COAX WITH STANDARD WIRE IN CERTAIN
APPLICATIONS
66
WIRING SYSTEM WEIGHT REDUCTION TECHNIQUES
DOWNGAUGING VS. SHIELD ELIMINATION
(WEIGHTS USED ARE TYPICAL)
24 GAUGE
SHIELDED WIRE
7.3 LBS/KFT
24 GA REG WIRE
2.5 LBS/KFT
66% REDUCTION
26 GAUGE
SHIELDED WIRE
6.2 LBS/KFT
15% REDUCTION
26 GA REG WIRE
1.8 LBS/KFT
75% REDUCTION
ORGANIZATION METHODOLOGY
• CIRCUITS ARE GROUPED BY AMPERAGE ONTO POWER RIBBONS
AND SIGNAL RIBBONS
• CIRCUITS ARE POSITIONED ON RIBBONS TO ELIMINATE
DETRIMENTAL CROSSTALK; FOR EXAMPLE,
- LOW IMPEDANCE GROUPING
- HIGH IMPEDANCE GROUPING
- SPIKE CIRCUITS POSITIONING
• HIGH AMPERAGE CIRCUITS MAY BE SEPARATED TO ENHANCE
HEAT DISSIPATION; FOR EXAMPLE,
- "ON/OFF" CIRCUIT SEQUENCING
• RESULTS IN RELIABLE, PREDICTABLE E3 PERFORMANCE
67
WIRING INTEGRATION UNITS
PERFORM MANY FUNCTIONS:
• CIRCUIT COLLECTION AND REDISTRIBUTION POINTS,
• RIBBONS HARNESS CIRCUIT ORGANIZATION POINTS,
• WIRE GAUGE CHANGE POINTS,
• RIBBON HARNESS/ENDPOINT HARNESS INTERFACE
WIU's CAN INCORPORATE:
• ACTIVE CIRCUITRY (RELAYS, IC'S, FUEL QUANTITY SYSTEM
SIMULATORS, ETC.),
• DISCRETE FILTERS,
• DATA BUS COUPLERS/FIBER OPTIC DECODERS,
• BUILT-IN-TEST (BIT) SYSTEMS,
• SYSTEM MONITORING CIRCUITRY, AND
• SELF-HEALING CAPABILITIES
68
• MODULARITY PROVIDES:
- SYSTEM GROWTH POTENTIAL AND SIMPLIFIES
MODIFICATION
- ENHANCED REPAIR CAPABILITIES BOTH ON AND OFF
AIRCRAFT
- THE CAPABILITY TO REPLACE DAMAGED/REPAIRED
HARNESSES AND WIUs TO BRING WIRING SYSTEM BACK
TO "LIKE NEW" CONDITION DURING THE ENTIRE SERVICE
LIFE OF THE AIRCRAFT
FOR THE FULL APPLICATION OF THE LOGISTICS SUPPORT
ANALYSIS (LSA) PROCESS TO WIRING SYSTEMS
- LIFE CYCLE COST SAVINGS
END POINT HARNESSES:
• ARE SHORT AND SIMPLE
• R&R AT "0" AND REPAIR AT "1"
• EASILY UPGRADED OR REPLACED FOR SYSTEM UPGRADES,
AND
• CAN INCORPORATE CERTAIN RIBBON HARNESS FEATURES
69
NAVAIR DIRECTIVE
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Front l[Roiq6
Tel A|floSllA
Vial A[KoStS
SUb_l CKAI_[ TO SD-2q
I, _Durtnl • eleven| omen| AiR-sq6, AZRoS16. end A[R-_II i_ yes deetded _o
revile perlreph 5.16.5 0£ SD-_I to foXlovet
O. ].14.5 IfZR[l_ - The lille1 mnd power distribution virinl shall be on
or|tatted wtrin8 eyetom eueh thmt lit oirluit8 ore maintained In the some
relettve polttion _e one mnother throulhout their entire Len|th. The
do|ill or the orllnited u£_ln8 system end the eeleetLon or tks eleetrtaei
iogBp4_letl lhJ|| be proposed by the oontreotor end epproved by NAVA|R.
Conventtonel eLoetrieei virilE.o,
2. Ue el_ oonour uith this epproeeh, tom preperinl • eeporete peokm|e thee
riLL be routed for A[R-O5 end AIR-ON endorsement oF thL8 ohonle,
3. |f there ore iny questLonl ay point oF eootoot Is Rr. Devtd Pieleeiero
592-T1_5, AIR-SqSDq
IIHI6DI AIR-S40 •
All-516 Olvts_nOIr_
BENEFITS OF ROI
• WEIGHT SAVINGS THROUGH ORGANIZATION AND
ELIMINATION OF INDIVIDUAL SHIELDS AND ASSOCIATED
HARDWARE
• LIFE CYCLE COST SAVINGS
• RELIABLE, PREDICTABLE E3 PERFORMANCE
• UTILIZES EXISTING TOOLS, LITTLE ADDITIONAL TRAINING
• DESIGN FLEXIBILITY TO MEET SYSTEM REQUIREMENTS
• INTERFACES WITH EXISTING AVIONICS
7O
ADVANTAGES OF WOVEN RIBBON ELEMENTS:
ROI RIBBONS:
• ARE NOT RESTRICTED TO "STANDARD" RIBBON WIDTHS,
• CAN INCORPORATE ANY GAUGE SIZE WIRES,
• MAY BE DESIGNED WITH A MIXTURE OF GAUGE SIZES,
• ARE EASILY FABRICATED, AND
• ARE COMPATIBLE WITH EXISTING FLEET MAINTENANCE
EQUIPMENT
ROI HARNESS TERMINATION FLEXIBILITY
ROi HARNESSES:
e ARE NOT DESIGN RESTRICTED TO ANY SPECIFIC CONNECTOR
TYPE,
• MAY BE TERMINATED USING EITHER RECTANGULAR OR
CIRCULAR CONNECTORS,
• ARE COMPATIBLE WITH MOST MILSPEC CONNECTORS,
• MAY BE CRIMPED OR SOLDERED, AND
• THE WIRES TERMINATE DIRECTLY INTO ALL CONNECTORS
WITHOUT THE USE OF ANY TRANSITIONAL ELEMENT
71
ROI HARNESSES REDUCE BATTLE DAMAGE EFFECTS
• ROI HARNESSES SUSTAIN MINIMAL DAMAGE FROM
PROJECTILE PENETRATION AS COMPARED TO
CONVENTIONAL WIRING BUNDLES,
• ROI DESIGN EXPEDITES BATTLE DAMAGE ASSESSMENT AND
REPAIRS,
• DAMAGED RIBBONS ARE "ZIPPED" BACK TOGETHER WITH
STANDARD CRIMP SPLICES WITHOUT THE NEED FOR I.D.
MARKING,
REPLACING SEVERLY DAMAGED ROI HARNESSES IS
PLAUSIBLE AND GREATLY SIMPLIFIED COMPARED TO
REPLACING CONVENTIONAL SPIDER HARNESSES.
A-6E RELIABILITY & MAINTAINABILITY (R&M) PYLON
ORIGINAL WEAPONS CONTROL SYSTEM IMPROVEMENT (WCSI) PYLON DESIGN
72
A-6E R&M PYLON
PYLON ROI LAYOUT
AIRCRAFT INTERFACE
WIRING INTEGRATION UNIT
"_ RIBBON HARNESS
BOMB RACK INTERFACE STORES INTERFACE WIRING
WIRING INTEGRATION UNIT INTEGRATION UNIT
V-22 WIRING IMPROVEMENT STUDY
WEIGHT SUMMARY 24 JAN 1991
MIDWING
HARNESS
REDUCTION
FULL AIRCRAFT
ESTIMATE *
REDUCTION
BASELINE ROI
239 LBS 132 LBS
...... 45%
1546 LBS 1185 LBS
23.4%
EXTRAPOLATED FROM MIDWING RESULTS USING BELL BOEING GROUND
RULES.
73
V-22 WIRING IMPROVEMENT STUDY
COST SUMMARY 24 JAN 1991
(MIDWING AREA ONLY)
R&D (NRE)
iNVESTMENT (PRODUCTION)
O_S (SPARES)
BASELINE
$ 1,216,600
$152,921,900
$ 6,108,800
$160,247,300
ROI
$ 1,473,300
$110,656,121
$ 3f571f700
$115,701,121
% REDUCTION 28%
1) BASED ON 913 A/C PRODUCTION RUN.
• OWS PROVIDES BENEFITS IN COST, WEIGHT, R&M, E3
PERFORMANCE, AND GROWTH POTENTIAL
• MODULARITY OF HARNESSES AND WIUs SIGNIFICANTLY
IMPROVES WIRING SYSTEM LOGISTICS SUPPORT
• COMPLETE ROI WIRING SYSTEM CURRENTLY BEING
DEVELOPED FOR THE V-22
• ORGANIZED WIRING TO BE APPLIED IN FUTURE AIRCRAFT
PLATFORMS AND REWIRE PROGRAMS
74
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Organized wiring systems

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