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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS1994

Problems with aging wiring in Naval aircraft

The Navy is experiencing a severe aircraft electrical wiring maintenance problem as a result of the extensive use of an aromatic polyimide insulation that is deteriorating at a rate that was unexpected when this wire was initially selected. This problem has significantly affected readiness, reliability, and safety and has greatly increased the cost of ownership of Naval aircraft. Failures in wire harnesses have exhibited arcing and burning that will propagate drastically, to the interruption of many electrical circuits from a fault initiated by the failure of deteriorating wires. There is an urgent need for a capability to schedule aircraft rewiring in an orderly manner with a logically derived determination of which aircraft have aged to the point of absolute necessity. Excessive maintenance was demonstrated to result from the accelerated aging due to the parameters of moisture, temperature, and strain that exist in the Naval Aircraft environment. Laboratory studies have demonstrated that MIL-W-81381 wire insulation when aged at high humidities followed the classical Arrhenius thermal aging relationship. In an extension of the project a multifactor formula was developed that is now capable of predicting life under varying conditions of these service parameters. An automated test system has also been developed to analyze the degree of deterioration that has occurred in wires taken from an aircraft in order to obtain an assessment of remaining life. Since it is both physically and financially impossible to replace the wiring in all the Navy's aircraft at once, this system will permit expedient scheduling so that those aircraft that are most probable to have wiring failure problems can be overhauled first.

Campbell, Frank J.↗
NASA NTRS1998

Cable Bundle Wire Derating

The allowable operating currents of electrical wiring when used in the space vacuum environment is predominantly determined by the maximum operating temperature of the wire insulation. For Kapton insulated wire this value is 200 C. Guidelines provided in the Goddard Space Flight Center (GSFC) Preferred Parts List (PPL) limit the operating current of wire within vacuum to ensure the maximum insulation temperature is not exceeded. For 20 AWG wire, these operating parameters are: 3.7 amps per wire, bundle of 15 or more wires, 70 C environment, and vacuum of 10(exp -5) torr or less. To determine the behavior and temperature of electrical wire at different operating conditions, a thermal vacuum test was performed on a representative electrical harness of the Hubble Space Telescope (HST) power distribution system. This paper describes the test and the results.

Lundquist, Ray A.↗
NASA NTRS1999

Cable Bundle Wire Derating

The allowable operating currents of electrical wiring when used in the space vacuum environment is predominantly determined by the maximum operating temperature of the wire insulation. For Kapton insulated wire this value is 200 degree C. Guidelines provided in the Goddard Space Flight Center (GSFC) Preferred Parts List (PPL) limit the operating current of wire within vacuum to ensure the maximum insulation temperature is not exceeded. For 20 AWG wire, these operating parameters are: (1) 3.7 amps per wire (2) bundle of 15 or more wires (3) 70 C environment (4) vacuum of 10(exp -5) torr or less To determine the behavior and temperature of electrical wire at different operating conditions, a thermal vacuum test was performed on a representative electrical harness of the Hubble Space Telescope (HST) power distribution system. This paper describes the test and the results.

Lundquist, Ray A.↗
NASA NTRS1998

Cable Bundle Wire Derating

The allowable operating currents of electrical wiring when used in the space vacuum environment is predominantly determined by the maximum operating temperature of the wire insulation. For Kapton insulated wire this value is 200 C. Guidelines provided in the Goddard Space Flight Center (GSFC) Preferred Parts List (PPL) limit the operating current of wire within vacuum to ensure the maximum insulation temperature is not exceeded. For 20 AWG wire, these operating parameters are: (1) 3.7 amps per wire; (2) bundle of 15 or more wires; (3) 70 C environment: and (4) vacuum of 10(exp -5) torr or less. To determine the behavior and temperature of electrical wire at different operating conditions, a thermal vacuum test was performed on a representative electrical harness of the Hubble Space Telescope (HST) power distribution system. This paper describes the test and the results.

Lundquist, Ray A.↗
NASA NTRS2000

Durability Evaluation of a Thin Film Sensor System With Enhanced Lead Wire Attachments on SiC/SiC Ceramic Matrix Composites

An advanced thin film sensor system instrumented on silicon carbide (SiC) fiber reinforced SiC matrix ceramic matrix composites (SiC/SiC CMCs), was evaluated in a Mach 0.3 burner rig in order to determine its durability to monitor material/component surface temperature in harsh environments. The sensor system included thermocouples in a thin film form (5 microns thick), fine lead wires (75 microns diameter), and the bonds between these wires and the thin films. Other critical components of the overall system were the heavy, swaged lead wire cable (500 microns diameter) that contained the fine lead wires and was connected to the temperature readout, and ceramic attachments which were bonded onto the CMCs for the purpose of securing the lead wire cables, The newly developed ceramic attachment features a combination of hoops made of monolithic SiC or SiC/SiC CMC (which are joined to the test article) and high temperature ceramic cement. Two instrumented CMC panels were tested in a burner rig for a total of 40 cycles to 1150 C (2100 F). A cycle consisted of rapid heating to 1150 C (2100 F), a 5 minute hold at 1150 C (2100 F), and then cooling down to room temperature in 2 minutes. The thin film sensor systems provided repeatable temperature measurements for a maximum of 25 thermal cycles. Two of the monolithic SiC hoops debonded during the sensor fabrication process and two of the SiC/SiC CMC hoops failed during testing. The hoops filled with ceramic cement, however, showed no sign of detachment after 40 thermal cycle test. The primary failure mechanism of this sensor system was the loss of the fine lead wire-to-thin film connection, which either due to detachment of the fine lead wires from the thin film thermocouples or breakage of the fine wire.

Lei, Jih-Fen↗
NASA NTRS2002

Wire Detection Algorithms for Navigation

In this research we addressed the problem of obstacle detection for low altitude rotorcraft flight. In particular, the problem of detecting thin wires in the presence of image clutter and noise was studied. Wires present a serious hazard to rotorcrafts. Since they are very thin, their detection early enough so that the pilot has enough time to take evasive action is difficult, as their images can be less than one or two pixels wide. Two approaches were explored for this purpose. The first approach involved a technique for sub-pixel edge detection and subsequent post processing, in order to reduce the false alarms. After reviewing the line detection literature, an algorithm for sub-pixel edge detection proposed by Steger was identified as having good potential to solve the considered task. The algorithm was tested using a set of images synthetically generated by combining real outdoor images with computer generated wire images. The performance of the algorithm was evaluated both, at the pixel and the wire levels. It was observed that the algorithm performs well, provided that the wires are not too thin (or distant) and that some post processing is performed to remove false alarms due to clutter. The second approach involved the use of an example-based learning scheme namely, Support Vector Machines. The purpose of this approach was to explore the feasibility of an example-based learning based approach for the task of detecting wires from their images. Support Vector Machines (SVMs) have emerged as a promising pattern classification tool and have been used in various applications. It was found that this approach is not suitable for very thin wires and of course, not suitable at all for sub-pixel thick wires. High dimensionality of the data as such does not present a major problem for SVMs. However it is desirable to have a large number of training examples especially for high dimensional data. The main difficulty in using SVMs (or any other example-based learning method) is the need for a very good set of positive and negative examples since the performance depends on the quality of the training set.

Kasturi, Rangachar↗
NASA NTRS2003

Effect Of Low External Flow On Flame Spreading Over ETFE Insulated Wire Under Microgravity

Fire safety is one of the most important issues for manned space missions. A likely cause of fires in spacecraft is wire insulation combustion in electrical system. Regarding the wire insulation combustion it important to know the effect of low external flow on the combustion because of the presence of ventilation flow in spacecraft. Although, there are many researches on flame spreading over solid material at low external flows under microgravity, research dealing with wire insulation is very limited. An example of wire insulation combustion in microgravity is the Space Shuttle experiments carried out by Greenberg et al. However, the number of experiments was very limited. Therefore, the effect of low flow velocity is still not clear. The authors have reported results on flame spreading over ETFE (ethylene - tetrafluoroetylene) insulated wire in a quiescent atmosphere in microgravity by 10 seconds drop tower. The authors also performed experiments of polyethylene insulated nichrom wire combustion in low flow velocity under microgravity. The results suggested that flame spread rate had maximum value in low flow velocity condition. Another interesting issue is the effect of dilution gas, especially CO2, which is used for fire extinguisher in ISS. There are some researches working on dilution gas effect on flame spreading over solid material in quiescent atmosphere in microgravity. However the research with low external flow is limited and, of course, the research discussing a relation of the appearance of maximum wire flammability in low flow velocity region with different dilution gas cannot be found yet. The present paper, therefore, investigates the effect of opposed flow with different dilution gas on flame spreading over ETFE insulated wire and change in the presence of the maximum flammability depending on the dilution gas type is discussed within the limit of microgravity time given by ground-based facility.

Nishizawa, Katsuhiro↗
NASA NTRS2006

Thermal Model of a Current-Carrying Wire in a Vacuum

A computer program implements a thermal model of an insulated wire carrying electric current and surrounded by a vacuum. The model includes the effects of Joule heating, conduction of heat along the wire, and radiation of heat from the outer surface of the insulation on the wire. The model takes account of the temperature dependences of the thermal and electrical properties of the wire, the emissivity of the insulation, and the possibility that not only can temperature vary along the wire but, in addition, the ends of the wire can be thermally grounded at different temperatures. The resulting second-order differential equation for the steady-state temperature as a function of position along the wire is highly nonlinear. The wire is discretized along its length, and the equation is solved numerically by use of an iterative algorithm that utilizes a multidimensional version of the Newton-Raphson method.

Border, James↗
NASA NTRS2004

Improved Method of Locating Defects in Wiring Insulation

An improved method of locating small breaches in insulation on electrical wires combines aspects of the prior dielectric withstand voltage (DWV) and time-domain reflectometry (TDR) methods. The method was invented to satisfy a need for reliably and quickly locating insulation defects in spacecraft, aircraft, ships, and other complex systems that contain large amounts of wiring, much of it enclosed in structures that make it difficult to inspect. In the DWV method, one applies a predetermined potential (usually 1.5 kV DC) to the wiring and notes whether the voltage causes any arcing between the wiring and ground. The DWV method does not provide an indication of the location of the defect (unless, in an exceptional case, the arc happens to be visible). In addition, if there is no electrically conductive component at ground potential within about 0.010 in. (approximately equal to 0.254 mm) of the wire at the location of an insulation defect, then the DWV method does not provide an indication of the defect. Moreover, one does not have the option to raise the potential in an effort to increase the detectability of such a defect because doing so can harm previously undamaged insulation. In the TDR method as practiced heretofore, one applies a pulse of electricity having an amplitude of less than 25 V to a wire and measures the round-trip travel time for the reflection of the pulse from a defect. The distance along the wire from the point of application of the pulse to the defect is then calculated as the product of half the round-trip travel time and the characteristic speed of a propagation of an electromagnetic signal in the wire. While the TDR method as practiced heretofore can be used to locate a short or open circuit, it does not ordinarily enable one to locate a small breach in insulation because the pulse voltage is too low to cause arcing and thus too low to induce an impedance discontinuity large enough to generate a measurable reflection. The present improved method overcomes the weaknesses of both the prior DWV and the prior TDR method.

Greulich, Owen R.↗
NASA NTRSDate not supplied

Short Circuiting the Controller – Missteps in Maintenance and Inspection of Process and Wiring in STS-93

The primary objective of the Space Transportation System mission 93 (STS-93) was to deploy the Chandra X-Ray Observatory. Chandra, the world's most powerful X-Ray telescope, allowed scientists from around the world to study some of the most distant and dynamic objects in the universe. Stripped of nearly 7,000 pounds of its own gear to make room for the payload, the orbiter assigned to this mission was Space Shuttle Columbia. Prior to STS-93, Columbia had flown 25 flights and was NASA's oldest and heaviest orbiter. On July 23, 1999, after two prior launch scrubs, Eileen Collins and her crew of four launched from Kennedy Space Center. About five seconds after launch, Mission Control at Johnson Space Center detected a voltage drop on one of Columbia's electrical buses. As a result of this power fluctuation, a primary and back-up Main Engine controller dropped offline. Given design redundancy, the two remaining controllers supported all three engines. If there had been any other AC bus issues, one engine of the three on the Orbiter would have shut down. The redundant set of digital computer units in each engine controller saved Columbia and her crew from a very risky contingency abort. Post-flight inspection revealed soot on a screw head and a hole in an adjacent Kapton insulated wire. The single strand of polyimide wire was located nearly half-way down the payload bay. The Shuttle Independent Assessment Team (SIAT) reported that the wire had rubbed and chaffed against a burred screw head. The burr was later determined to be the result of overtightening of the screw by a technician during a maintenance refurbishment. Alone, the burr may not have been problematic, but later, during another ground processing event, possibly years after, someone inadvertently stepped on the wiring harness. With the pressure and motion of unintended contact, some of the Kapton insulation rubbed off against the burred screw head. The SIAT suspected the wire damage was pre-existing and was caused 4 or 5 years prior to the flight. Finally, the intense vibrations during the launch sequence allowed contact between the exposed conductor and exposed metal area on the burred screw head, resulting in the arcing and shorting of the wire. Due to the quick turnaround times of Space Shuttle Orbiters, wiring issues caused from multiple maintenance events were often overlooked. Additionally, failing to incorporate thorough and early inclusion of human systems integration (HSI) applications as a crucial part of the decision process can result in these types of misshaps. In order to reduce human error associated with integrated manufacturing, maintenance, refurbishment and flight preparations, wire inspection criteria should be refined and standardized, visual inspection processes should be quantified, and technicians should be certified by specially trained instructors. This case, among many others, unveils why human error management and development of safety metrics is a vital piece in the development of complex systems, and why it should be supported aggressively and implemented program wide.

Human Systems Integration↗
DOE OSTI2025

Voltage-Current Behavior of a Superconducting STAR ® Wire in a 6-Around-1 Cable Configuration

A 6-around-1 transposed cable using superconducting STAR® wires can be useful for future circular collider applications. We made three cable samples using single STAR® wires with a diameter of 1.3 mm. The first two samples, made with a cabling machine, used STAR® wires consisting of a 0.7 mm diameter Nb-Ti core. The third cable sample was manually wound and used a STAR® wire made with a 0.81 mm diameter Cu core. The first sample showed severe degradation after the cable was bent to a 75 mm radius. The current-carrying capability of the innermost and outermost REBCO tapes in the STAR® wire degraded by 42% to 98% and the middle REBCO tapes remained intact. This was also the case for the second and straight cable sample. After fabrication of the third cable sample, we observed only about 5% reduction in the current along the wire, measured at different locations inside the terminations. Finally, the results indicate that the differences in architecture or fabrication of the STAR® wires could have caused differences in critical current retention after cabling.

6-around-1 cable↗
DOE OSTI2025

Analysis Background & Noise in Stretched Wire Alignment Technique Measurements

The Stretched-Wire Alignment Technique (SWAT) is one method of magnet alignment for linear induction accelerators. The applications of SWAT have been implemented for aligning solenoid magnets on the Scorpius linear induction accelerator which will be sited at the Nevada National Security Site and the Flash X-Ray (FXR) linear induction accelerator at Lawrence Livermore National Laboratory’s Contained Firing Facility. This article describes both systematic (repeatable) and random sources of background and noise as well as practical ways to eliminate or reduce them to acceptable levels. Systematic sources include reflections from wire ends, rapid sag due to ohmic heating of the wire, magnetic materials, and shot rate. Random sources include air currents, vibration of nearby equipment, mechanical stability of test equipment, and the instruments used to measure the wire motion. Mitigations include curve fitting and adaptive noise signal cancellation, and mechanical damping. Finite Element Analysis (FEA) was used to identify and resolve a repeatable wire vibration frequency interfering with the signal resolution. Two stretched wire alignment technique set ups from Sandia National Labs and Lawrence Livermore National Lab have shown background noise sources and ways of mitigating them by either analysis methods or change of mechanical configuration. Conclusions that were drawn included the severe sensitivity of the deflection to even small external interferences of the SWAT wire such that it requires attention to detail in mechanical set up and analysis.

Linear Inductive Accelerator↗
DOE OSTI2025

Investigating Electron Conductivity Regimes in the Bacterial Cytochrome Wire OmcS

The anaerobic bacterium Geobacter sulfurreducens produces extracellular, electronically conductive cytochrome polymer wires that are conductive over micron length scales. Structure models from cryo-electron microscopy data show OmcS wires form a linear chain of hemes along the protein wire axis, which is proposed as the structural basis supporting their electronic properties. However, the mechanism by which this heme arrangement supports long-range electronic conduction remains unknown. Structure models from cryo-electron microscopy data show these wires form a linear chain of hemes along the protein wire axis, which is proposed as the structural basis supporting their electronic properties. Existing computational models using static heme redox potentials and coupling energies fail to explain experimental observations, predicting conductances 10,000 to 100,000 times lower than measured values. Here, we investigate how dynamic disorder affects site energies, interheme coupling, and long-range electronic conductivity within these cytochrome wires. We introduce an approach to extract charge carrier site information directly from Kohn–Sham density functional theory, without employing projector schemes, and show that site and coupling energies are highly sensitive to changes in interheme geometry and the surrounding electrostatic environment. Unlike models that incorporate dynamic disorder as a thermally averaged quantity, our quantum charge carrier model incorporates proxies for dynamic disorder through decoherence corrections, yielding predicted diffusion coefficient closer to what is expected from experiment and comparable with other organic-based electronic materials. Based on these simulations, we propose that the instantaneous fluctuations of the local electrostatic environment can transiently lift energy degeneracies and delocalize charge carriers. Furthermore, these studies reveal how incorporating dynamic fluctuations associated with the environment resolves the discrepancy between theory and experiment in microbial cytochrome wires and highlight design principles for bioinspired, heme-based conductive materials.

Bioinorganic chemistry↗
NASA NTRS1972

Development of explosively bonded TZM wire reinforced Columbian sheet composites

Methods of producing TZM molybdenum wire reinforced C129Y columbium alloy composites by explosive welding were studied. Layers of TZM molybdenum wire were wound on frames with alternate layers of C129Y columbium alloy foil between the wire layers. The frames held both the wire and foils in place for the explosive bonding process. A goal of 33 volume percent molybdenum wire was achieved for some of the composites. Variables included wire diameter, foil thickness, wire separation, standoff distance between foils and types and amounts of explosive. The program was divided into two phases: (1) development of basic welding parameters using 5 x 10-inch composites, and (2) scaleup to 10 x 20-inch composites.

Otto, H. E.↗
NASA NTRS1976

Impact tensile testing of wires

The test consists of fixing one end of a wire specimen and allowing a threaded falling weight to strike the other. Assuming the dynamic stress in the wire to be a function only of its strain, energy considerations show for negligible wire inertia effects that the governing dynamic stress-strain law can be determined directly from impact energy vs. wire elongation data. Theoretical calculations are presented which show negligible wire inertia effects for ratios of wire mass to striking mass of the order of .01 or less. The test method is applied to soft copper wires and the dynamic stress-strain curve so determined is found to be about 30 percent higher than the corresponding static curve.

Dawson, T. H.↗
NASA NTRS1978

Wire stripper

An insulation stripper is described which is especially useful for shielded wire, the stripper including a first pair of jaws with blades extending substantially perpendicular to the axis of the wire, and a second pair of jaws with blades extending substantially parallel to the axis of the wire. The first pair of jaws is pressed against the wire so the blades cut into the insulation, and the device is turned to form circumferential cuts in the insulation. Then the second pair of jaws is pressed against the wire so the blades cut into the insulation, and the wire is moved through the device to form longitudinal cuts that permit easy removal of the insulation. Each of the blades is located within the concave face of a V-block, to center the blades on the wire and to limit the depth of blade penetration.

Economu, M. A.↗
NASA NTRS1995

Hot-wire calibration in subsonic/transonic flow regimes

A different approach for calibrating hot-wires, which simplifies the calibration procedure and reduces the tunnel run-time by an order of magnitude was sought. In general, it is accepted that the directly measurable quantities in any flow are velocity, density, and total temperature. Very few facilities have the capability of varying the total temperature over an adequate range. However, if the overheat temperature parameter, a(sub w), is used to calibrate the hot-wire then the directly measurable quantity, voltage, will be a function of the flow variables and the overheat parameter i.e., E = f(u,p,a(sub w), T(sub w)) where a(sub w) will contain the needed total temperature information. In this report, various methods of evaluating sensitivities with different dependent and independent variables to calibrate a 3-Wire hot-wire probe using a constant temperature anemometer (CTA) in subsonic/transonic flow regimes is presented. The advantage of using a(sub w) as the independent variable instead of total temperature, t(sub o), or overheat temperature parameter, tau, is that while running a calibration test it is not necessary to know the recovery factor, the coefficients in a wire resistance to temperature relationship for a given probe. It was deduced that the method employing the relationship E = f (u,p,a(sub w)) should result in the most accurate calibration of hot wire probes. Any other method would require additional measurements. Also this method will allow calibration and determination of accurate temperature fluctuation information even in atmospheric wind tunnels where there is no ability to obtain any temperature sensitivity information at present. This technique greatly simplifies the calibration process for hot-wires, provides the required calibration information needed in obtaining temperature fluctuations, and reduces both the tunnel run-time and the test matrix required to calibrate hotwires. Some of the results using the above techniques are presented in an appendix.

Nagabushana, K. A.↗
NASA NTRS1995

NASA wiring for space applications program

An overview of the NASA Wiring for Space Applications Program and its relationship to NASA's space technology enterprise is given in viewgraph format. The mission of the space technology enterprise is to pioneer, with industry, the development and use of space technology to secure national economic competitiveness, promote industrial growth, and to support space missions. The objectives of the NASA Wiring for Space Applications Program is to improve the safety, performance, and reliability of wiring systems for space applications and to develop improved wiring technologies for NASA flight programs and commercial applications. Wiring system failures in space and commercial applications have shown the need for arc track resistant wiring constructions. A matrix of tests performed versus wiring constructions is presented. Preliminary data indicate the performance of the Tensolite and Filotex hybrid constructions are the best of the various candidates.

Schulze, Norman↗