View Latest Blog Entries
Close
Categories
Testing & Assessment Certification Aging Wires & Systems Management Standard & Regulation Conference & Report Maintenance & Sustainment Research Protection & Prevention Arcing Miscellaneous
Popular Tags
Visual Inspection MIL-HDBK MIL-HDBK-525 FAR AS50881 FAR 25.1707 High Voltage Electromagnetic Interference (EMI) Wire System Maintenance Arcing Damage FAR 25.1709
All Tags in Alphabetical Order
25.1701 25.1703 Accelerated Aging ADMT Aging Systems Aircraft Power System Aircraft Service Life Extension Program (SLEP) arc damage Arc Fault (AF) Arc Fault Circuit Breaker (AFCB) Arc Track Resistance Arcing Arcing Damage AS22759 AS22759/87 AS4373 AS4373 Method 704 AS50881 AS5692 AS6019 AS85485 AS85485 Wire Standard ASTM F2799 ATSRAC Attenuation Automated Wire Testing System (AWTS) Bent Pin Analysis Best of Lectromec Best Practice Cable cable testing Carbon Nanotube (CNT) Certification Chafing Chemical Testing Circuit Breaker circuit design Circuit Protection Coaxial cable cold bend comparative analysis Compliance Component Selection Condition Based Maintenance Conductor conduit Connector connectors contacts Corona Corrosion Corrosion Preventing Compound (CPC) Cracking D-sub data analysis data cables degradat Degradation Delamination Derating diagnostic dielectric constant Distributed Power System DO-160 Electrical Aircraft Electrical Component Electrical Testing Electromagnetic Interference (EMI) Electromagnetic Vulnerability (EMV) EMC EMF EN3197 EN3475 EN6059 End of Service Life End of Year Energy Storage engines Environmental Environmental Cycling ethernet EWIS Component EWIS Design EWIS Failure EWIS Thermal Management EZAP FAA AC 25.27 FAA AC 25.981-1C Failure Database Failure Modes and Effects Analysis (FMEA) FAQs FAR FAR 25.1703 FAR 25.1707 FAR 25.1709 fault tree Fixturing Flammability fleet reliability Flex Testing fluid exposure Forced Hydrolysis fuel system fuel tank ignition functional testing Fundamental Articles Future Tech Green Taxiing Grounding Harness Design Hazard Analysis health monitoring heat shrink tubing high current high Frequency high speed data cable High Voltage History Hot Stamping Humidity Variation ICAs IEC60172 Instructions for Continued Airworthiness Insulation insulation resistance IPC-D-620 ISO 17025 Certified Lab Kapton Laser Marking life limited parts life projection Maintenance Maintenance costs Mandrel Mechanical Testing MECSIP MIL-C-38999 MIL-C-85485 MIL-DTL-17 MIL-DTL-3885G MIL-DTL-38999 MIL-E-25499 MIL-HDBK MIL-HDBK-1646 MIL-HDBK-217 MIL-HDBK-454 MIL-HDBK-516 MIL-HDBK-522 MIL-HDBK-525 MIL-HDBK-683 MIL-STD-1560 MIL-STD-1798 MIL-STD-464 MIL-T-7928 MIL-T-81490 MIL-W-22759/87 MIL-W-5088 Military 5088 modeling MS3320 NASA NEMA27500 No Fault Found off gassing Outgassing Overheating of Wire Harness Parallel Arcing part selection Performance physical hazard assessment Physical Testing polyimdie Polyimide-PTFE Power over Ethernet Power systems predictive maintenance Presentation Probability of Failure Product Quality Radiation Red Plague Corrosion Reduction of Hazardous Substances (RoHS) regulations relays Reliability Research Rewiring Project Risk Assessment SAE Secondary Harness Protection Separation Requirements Series Arcing Service Life Extension Severe Wind and Moisture-Prone (SWAMP) Severity of Failure Shield Shielding signal cable silver plated wire smoke Solid State Circuit Breaker Space Certified Wires stored energy supportability Sustainment Temperature Rating Temperature Variation Test methods Test Pricing Testing Thermal Circuit Breaker Thermal Endurance Thermal Index Thermal Shock Thermal Testing Tin plated conductors Troubleshooting TWA800 UAVs verification Visual Inspection voltage white paper whitelisting Wire Ampacity Wire Certification Wire Comparison wire damage wire failure wire properties Wire System wire testing Wire Verification work unit code

Frequency of Wire System Incidents

Aging Wires & Systems

In July 2017, Lectromec published a white paper on electrical wiring system failures on commercial aircraft. This is a brief video of the findings and what can be done to improve EWIS reliability in commercial aircraft.

Video Transcript: Hello, I am Mike Traskos with Lectromec and today I will talk about results from our analysis of electrical wiring system failures on commercial aircraft in 2016.

The wiring systems of modern aircraft are complicated. Each has tens to hundreds of miles a wire and thousands of connectors and supporting electrical system components. It should not be a surprise that as aircraft age, the components age and they become more susceptible to wiring failures.

To determine the extent and frequency of EWIS failures on commercial aircraft, Lectromec reviewed thousands of service difficulty reports filed with the FAA. Our analysis of the 2016 data found that aircraft, older than 20 years old, are twice as likely to have EWIS failures than those in the 10-15 year bracket.

In a perfect world, these failures would be benign and only have a limited impact on the aircraft reliability. Lectromec’s analysis of the 2016 data suggests that 5% of EWIS failures resulted in an Emergency Landing diversion or aborted takeoff. This corresponds with one major EWIS failure per week; a slight increase from similar analysis Lectromec did on data from 2010 to 2014.

The data further showed 15% of EWIS failures resulted in the aircraft being grounded for a sustained period.

And to go beyond this, EWIS failures are underreported. I had the opportunity to talk with a maintenance engineer from a major airline who read through our white paper and I was told that the EWIS problems they have within their fleet noticeably exceed what gets reported to the FAA.

So of course, the question is if these numbers and failures a result of component wear out, maintenance failures, or poor design? The answer could be one or all three of these. But until the wiring system health, maintenance, and certification are reviewed is impossible to know how best to address the problem within your organization.

As a starting point, I recommend reading our white paper on EWIS failures. We provide some recommendations on what you can do within your own fleet to improve performance.

Also, if you want to be proactive evaluate your wiring system with the same rigor you would for your structures and engines, contact Lectromec. We can get you from weight wire to where you need to be.

Thank you for your time.

Michael Traskos

Michael Traskos

President, Lectromec

Michael has been involved in wire degradation and failure assessments for more than a decade. He has worked on dozens of projects assessing the reliability and qualification of EWIS components. Michael is an FAA DER with a delegated authority covering EWIS certification and the chairman of the SAE AE-8A EWIS installation committee.