Air Force Materiel Command Developing Fielding and Sustaining

Air Force Materiel Command Developing, Fielding, and Sustaining America’s Aerospace Force Aging Aircraft Wiring Randy Hall Program Manager Aging Aircraft SPO Aeronautical Systems Center Integrity - Service - Excellence

Aging Aircraft Wiring Overview • Field Wiring Issues (The Problem) • • • User Identified Issues/Requirements AA Focus Areas Strategic Goals/Objectives Wiring Action Plan Other Federal Programs Summary 10/15/2021 2

Field Wiring Issues The Problems • Wiring failures can be safety issues – TWA 800 • Environment and location plays major role in wire failures – High stress areas (thermal and vibration) – Oil and fluid contamination – Tensile loads on wires (sometimes shortened by repairs) • Wiring databases are non-existent/limited – No consistent specific work unit codes for wiring maintenance 10/15/2021 3

Field Wiring Issues Primary Areas of Concern • Connectors and terminators – Most wire failures found near connector or terminator – Typical problems are pin retention, shielding breaks and broken wires • Chafing • Splices and field modifications involving wiring • Wiring protection methods – Convoluted tubing, extra heat shrink, clamping, teflon tape, spiral wrap and tie strings can all hinder visually finding faults 10/15/2021 4

Field Wiring Issues Maintenance Problems • Most training for wire fault detection by OJT • Inadequate Technical Orders (TOs) – Do not instruct user to look at wiring – Do not list tolerances for failure criteria • Wiring problems are TIME CONSUMING – Trouble shooting/repairing wiring can take 10 to 15 times longer than component replacement – Inaccessibility to wiring increases difficulty of repair • Different approaches to wire testing needed depending on aircraft type 10/15/2021 5

Field Wiring Issues Maintenance Problems Cont: • Most problems found during troubleshooting of a system “fault” • Intermittent problems difficult to troubleshoot – Problems appear solved on ground checks – Reoccur in the air – Sometimes due to load vs no-load conditions • Multi-meters typically current troubleshooting tool to find wiring failures – Not always sensitive enough to “pin point” location or failure mode 10/15/2021 6 – Labor intensive techniques to isolate faults

User Identified Issues/Requirements Desired Improvements • Enhanced Training of Wiring Fault Awareness: – – Known to the Unknown Chafing awareness improvements in general T. O. Tool use, repair techniques, preventative maintenance Importance of proper maintenance data collection • Repair process improvements • Improved data collection, identification (MDS) – Improve data collection/reporting systems across wiring systems – Feedback loop • Rapid transition of available/advanced technology • Predictive analysis tools to evaluate integrity and 10/15/2021 7 project life expectancy

AA Initial Focus Areas • Focus Areas: – Diagnostics – Modernization – Data Management and Analysis – Failure Mechanisms/Characterization • Area Selection Based on: – Cost, Readiness, and Manpower Impacts – Users identified as problem areas – Known Deficiencies 10/15/2021 8

Wire Integrity Strategic Plan Wire System Integrity Goals • Address existing and evolving User needs • Prevent safety-related problems caused by corrosive & deteriorating effects on nonstructural components of aging aircraft • Transition wiring system maintenance from a reactive to a proactive philosophy • Develop & implement a management strategy to address aircraft total force wiring system life cycle needs 10/15/2021 9

Wire System Integrity Objectives • Management Information – Collect/organize management information necessary from AF and other Agencies • Data Management – Modify existing data management systems • Tool Set Development – Develop/apply a tool set that addresses the spectrum of aging wiring issues • Process Improvement – Improve policies/processes that currently control wiring systems 10/15/2021 10

Wire System Integrity Objectives (cont. ) • Aging Wiring Working Group – Modify the working group mission to address wiring system life-cycles and lessons learned • Establish Subcommittees for Specific Issues – – – Training Improved Fault ID Improve data collection/predictive analysis Advanced technology and transition Communications • Advanced Technology Application – Improve wiring system safety/integrity through development/application of advanced technologies within all phases of the wiring system life-cycle 10/15/2021 11

Wiring Action Plan • Organized USAF Aging Aircraft Wiring Working Group (AAWWG) – First meeting held 17 -18 July 2001 – Second meeting scheduled for 12 -13 Feb 2002 • Team with AFRL – – Collaborate with other government agencies Partnership with industry Ensure technology is suitable for field use Transition proven advanced technology • Develop Strategic Goals & Get Well Plan – Provide new or modified data collection system 10/15/2021 12

Wiring Action Plan • Develop Strategic Goals & Get Well Plan (continued) – Form subcommittees to the AAWWG to identify issues and recommend possible solutions to aging wiring issues – Share AAWWG ideas and lessons learned with other weapon systems that may be experiencing similar wiring issues – Develop an AF strategy that addresses aging wiring system issues based on User, Depot and Program Office needs and priorities 10/15/2021 13

Other Federal Programs 10/15/2021 14

Other Federal Programs 10/15/2021 15

Current Forums • Aging Wire and Inert Gas Generator Group (AWIGG) • Aging Aircraft Wiring Working Group (AAWWG) • Naval Aerospace Vehicle Wiring Action Group (NAVWAG) • Cable Harness Repair or Manufacturing Equivalent (CHROME) • ASC/AFRL IPT • Society of Automotive Engineering (SAE) Committee AE-8 A • Aging Transport Systems Oversight Committee (ATSRAC FAA) 10/15/2021 16

Summary • • Field Wiring Issues (The Problem) User Identified Issues/Requirements AA Focus Areas Strategic Goals/Objectives Wiring Action Plan Other Federal Programs Current Forums 10/15/2021 17