Browse Topic: Wiring

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This digital standard is a requirements extract of AS50881H Wiring Aerospace Vehicle. This file contains a general requirements extraction as well as files that are optimized for use with Doors Classic, Siemens Polarian, and PTC. AS7140 Data Model
This specification covers design requirements, performance requirements, and methods of procurement for tools and associated accessories used to strip aerospace vehicle electrical wire and cable. Aerospace vehicle electrical wire has stranded conductors with protective plating and specialized insulation. Poor quality wire strippers or mismatched blades can compromise the performance of wiring.
AE-8C2 Terminating Devices and Tooling Committee
Describes the relative measurement of assessing the damage zone of arc plasma to determine appropriate separation/segregation requirements between a wire harness and nearby components
AE-8A Elec Wiring and Fiber Optic Interconnect Sys Install
As per Committee/Henry E. Harschburger recommendations
A-6B1 Hydraulic Servo Actuation Committee
This paper deals with the influence of engine failure during hover on the wiring harness mass of electrical Vertical Take-Off and Landing (eVTOL) aircraft. It starts by presenting possible strategies which can be used to distribute the additional thrust needed during an engine failure among the remaining engines. The most efficient strategy is selected and the impact of different single engine failures on the overall thrust share, while using this strategy, is discussed. The paper proceeds by applying the selected thrust compensation strategy to the mission simulation of three common reference models, which are representative of current eVTOL aircraft configurations. This simulation is used to determine the worst flight phase for the One Engine Inoperative (OEI) condition to occur. The main purpose of the simulation is to optimize the wire sizes of the wiring harness of each configuration while satisfying different design objectives. The results of these optimizations are used to discuss the criticality of each engine failure and its influence on the wiring harness design, especially its mass. It concludes with design recommendations for the wiring harness of eVTOL aircraft.
Oberschwendtner, SebastianHornung, Mirko
An essential component for the advancement of autonomous flight lies in the development of an intelligent routing system designed to facilitate the maintenance and troubleshooting of electrical wiring. Utilizing software with the capability to present routed paths in a computer-aided design (CAD) format allows for a detailed representation of the rules governing the layout of wiring around structural supports and distribution channels. Despite this, three-dimensional (3D) methodologies have yet to fully incorporate critical data related to the characterization of individual wiring signals, hindering automatic routing. This paper underscores a competitive edge that can be achieved by expanding 3D capabilities to accurately depict the current state of wiring signals in terms of temperature, humidity, electromagnetic frequency, amperage, and other relevant factors. Achieving this involves integrating a non-intrusive smart sensing technology with the intelligent routing system to monitor and diagnose the health and integrity of the wiring system. With this integration, a more robust artificial intelligence (AI) system can leverage the obtained data to make more precise decisions, enhancing overall system performance.
Rhysing, Daryian
Recent field experience has indicated significant problems with some types of wire and cables as routed on aircraft landing gear. This SAE Aerospace Information Report (AIR) is intended to identify environmental concerns the designer should consider, materials that appear to be most suitable for use in these areas, routing, clamping, and other protection techniques that are appropriate in these applications. In recent years aircraft certification regulatory agencies introduced new regulations regarding Electrical Wiring Interconnection Systems (EWIS) to further enhance safety of the associated systems and aircraft overall.
A-5B Gears, Struts and Couplings Committee NEW Name Goes Her
This SAE Standard covers unshielded cable, 22 gauge and larger, intended for use at a nominal system voltage up to 600 V or 1000 V (ACrms or DC). It is intended for use in surface vehicle electrical systems.
Cable Standards Committee
The scope of this report is to capture fundamental principles of selecting a wire size for an aerospace application using the method prescribed in the AS50881 standard and additional calculations, not found in AS50881, to ensure the wire selection will adequately perform in the specific physical and environment conditions. This report covers wire selection and sizing as part of the electrical wire interconnection systems (EWIS) used in aerospace vehicles. Aerospace vehicles include manned and unmanned airplanes, helicopters, lighter-than-air vehicles, missiles, and external pods. This document does not apply to wiring inside of airborne electronic equipment but shall apply to wiring externally attached to such equipment. Wire selection must consider physical and environmental factors to size wires such that they have sufficient mechanical strength, do not exceed allowable voltage drop levels, are protected by materials or circuit protection devices, and meet circuit current carrying requirements. For electrical power feeders and distribution or EWIS applications, other information and environmental and installation limitations are also needed to adequately evaluate and select the correct wire size for a specific application and meet design requirements. The report presents only fundamental principles and guidelines and cannot adequately cover all aspects and complexities associated with wire selection and sizing. Some of the calculations in this report have been simplified to demonstrate the process for validating a wire size selection for a design application. More precise calculations should be investigated and evaluated to ensure proper assessment of each individual calculation in this report.
AE-7C Systems
“Rds_on” Based OBD for Pre-Supply Fuel Pump Driver ModulesSAE-PP-001601/26/2021
In automotive electronics on-board diagnostics does the fault diagnosis and reporting. It provides the level of robustness required for the control electronics against various faults. The amount of diagnostic information available via on board diagnostics are depends on the type of vehicle. Pre-supply fuel pump is the component in the common rail hydraulic system. It pumps the fuel from the fuel tank to the inlet valve of the high pressure fuel pump. Electronic control unit synchronizes its operation with high pressure fuel pump. A dedicated driver module in the ECU controls the operation of pre-supply fuel pump. The driver module consist of an ASIC with internal voltage, current monitoring modules for the fault diagnosis and the pre-drivers to control external HS and LS power stages. The software part of the OBD programmed in the internal memory of the ASIC. The “Rds_on” of the power MOSFETs are used for the fault detection purpose. The module designed to operate in dual frequencies and variable duty cycles. It ensures the optimum hydraulic performance of the pump and provides maximum possible diagnostic coverage against various faults. The on-board diagnosis against the faults such as motor inrush current, rotor Lock, short circuit to ground, short circuit to battery, line to line fault (short circuit between high side and low side pins) and open load are discussed in this paper. The wiring harness impedance has significant influence on the fault detection duration. The wiring harness length depends on the position of ECU and pump in the vehicle. Pre-supply fuel pump normally immersed in the fuel tank and ECU normally kept either in the dash board or mounted on the body of engine. The resistance and inductance of the wiring harness are the functions of wire diameter and length. The below are the parameters influences the fault diagnostics of the driver module discussed in this paper. • Fault detection threshold (Vth), • The “Rds_on” of the MOSFET, • Fault current magnitude, • Frequency at which power stage operates, • Duty cycle, • Thermal response of the MOSFET, • Safe operating conditions, • Blind bands and MOSFET turn on/off delays. These parameters possesses typical relationships each another depending on the operating modes of engine and ambient conditions.
MobrxivNonAdmin, Lindsay
The purpose of this SAE Aerospace Recommended Practice (ARP) is to provide recommendations for marking wire and cable insulations to meet legibility requirements. This information is generic and applies to any type of wire marking system, such as an ultraviolet (UV) laser marking system or an inkjet or other ink based wire marking system. This ARP is limited to the legibility of human-readable characters and does not address bar code or other machine-readable symbols. In this ARP, the term wire refers to jacketed cables and fiber optic cables in addition to individual wires. This ARP defines the factors that affect the legibility of markings on wiring. Two generic types of variables affect legibility: stimulus variables and environmental variables. Stimulus variables are those factors involving the mark itself. This ARP establishes a set of guidelines for key stimulus variables that contribute to legibility and which should be taken into consideration in the course of specifying and using wire marking equipment. Environmental variables affect the reading of the marking, for example lighting, observer-stimulus distance, orientation of observer to stimulus, clutter, visual acuity of observer, state of mind, and visual exposure duration.
AE-8A Elec Wiring and Fiber Optic Interconnect Sys Install
This SAE Aerospace Standard (AS) defines the items that shall be considered when creating a fiber optic cable assembly specification and source control drawing intended for installation on aerospace platforms.
AS-3 Fiber Optics and Applied Photonics Committee
This paper deals with the influence of the wiring harness on the system performance of electric vertical take-off and landing (eVTOL) aircraft. The architecture and connections of the wiring harness are formalized using graph theory. The adjacency and incidence matrices provided by algebraic graph theory are used to define the harness connections and links. The current flows within the harness are calculated by applying Kirchhoff’s and Ohm's law to the network equations. Three common reference models are used to simulate and optimize different harness architectures. The harness architectures differ in the kind of connection and number of harness links. The optimization is done using two objectives. One objective is to maximize the range of the aircraft. The other objective, to minimize the harness mass, is used to show the performance difference of such a wiring harness. The influence of the system voltage and the take-off mass are examined as well. The results of the optimizations show, that a wiring harness exists for each configuration which maximizes the range of the aircraft. This optimal wiring harness is not the wiring harness with the lowest mass.
Oberschwendtner, SebastianHornung, Mirko
This SAE Aerospace Information Report (AIR) is limited to the subject of compatibility of wiring as part of aircraft Electrical Wiring and Interconnect Systems (EWIS) installed in and around aircraft fuel tanks.
AE-8A Elec Wiring and Fiber Optic Interconnect Sys Install
Fundamentals in Wire Selection and Sizing for Aerospace ApplicationsAIR6540A (Historical)3/6/2020
The scope of this report is to capture fundamental principles of selecting a wire size for an aerospace application using the method prescribed in the AS50881 standard and additional calculations, not found in AS50881, to ensure the wire selection will adequately perform in the specific physical and environment conditions. This report covers wire selection and sizing as part of the electrical wire interconnection systems (EWIS) used in aerospace vehicles. Aerospace vehicles include manned and unmanned airplanes, helicopters, lighter-than-air vehicles, missiles, and external pods. This document does not apply to wiring inside of airborne electronic equipment but shall apply to wiring externally attached to such equipment. Wire selection must consider physical and environmental factors to size wires such that they have sufficient mechanical strength, do not exceed allowable voltage drop levels, are protected by materials or circuit protection devices, and meet circuit current carrying requirements. For electrical power feeders and distribution, or EWIS applications, other information and environmental and installation limitations are also needed to adequately evaluate and select the correct wire size for a specific application and meet design requirements. The report presents only fundamental principles and guidelines and cannot adequately cover all aspects and complexities associated with wire selection and sizing. Some of the calculations in this report have been simplified to demonstrate the process for validating a wire size selection for a design application. More precise calculations should be investigated and evaluated to ensure proper assessment of each individual calculation in this report.
AE-7C Systems
This document presents design and application information which will allow optimized utilization of filter line wire and cable purchased to AS85485. Filter line wire is defined and design information is presented. The electrical and mechanical performance characteristics of the wire, along with recommended harnessing methods and techniques, are also presented.
AE-8A Elec Wiring and Fiber Optic Interconnect Sys Install
Performance Specification for Cable-to-Terminal Electrical CrimpsUSCAR21-4 (Current)1/22/2020
This specification defines test methods and requirements for validation of solderless crimped connections. The purpose of this test is to simulate in the lab the stress seen in a typical life (15 years and 150000 miles) for a crimp connection and assure the crimp is mechanically strong and electrically stable. This specification was developed for use with stranded automotive copper wire. Only where specifically mentioned are other constructions or other core materials (aluminum, clad, steel core, etc.) applicable. This specification does not apply to wire types not mentioned, such as coaxial cable crimps, unless a USCAR-21 test is specifically referenced in the test specification for that wire type. This specification is based on accepted levels of environmental exposure for automotive applications. In any intended vehicle application, if the products covered by this specification are or may be subjected to conditions beyond those described in this document, they must pass special tests simulating the actual conditions to be encountered before they can be considered acceptable for actual vehicle application. Products certified by their supplier as having passed specific applicable portions of this specification are not to be used in applications where conditions may exceed those for which the product has been satisfactorily tested. Any deviation must be documented and included in the final test report. Crimp applications validated to this specification are intended to supersede crimp information on the component prints. The terminal supplier has the primary responsibility for testing and selection of crimp tooling and to supply detailed crimp information or make crimp tooling available to the wiring assembly supplier actually doing the production crimping. The wiring harness supplier is responsible for validating all crimps produced per this specification. Environmental exposures called-out in this specification include Thermal Shock and Temperature Humidity Cycling and are used to stress every production terminal and cable combination used under test to simulate field exposure. SAE/USCAR-21 has tests that will detect deficiencies in crimp tooling geometry, plating quality, strand distribution, and cable strand count. SAE/USCAR-21 must be done in addition to a connector system validation such as SAE/USCAR-2 to assure the entire allowable production crimp height range of every combination is acceptable. Testing to a connector system specification also validates what is not tested in SAE/USCAR-21 such as long-term high temperature exposure. Procedures included within this specification are intended to cover performance testing and development of electrical terminal crimps that are part of the electrical connection systems in low voltage (0 to 48 VDC) road vehicle applications at ambient temperatures of 125 °C maximum. Higher voltages and temperatures may be tested if the OEM customer approves use of these test procedures for use at voltages and temperatures beyond these limits.
USCAR
Next Generation Power Distribution Unit in Wiring Harness2019-28-257111/21/2019
With the exponential advancement in technological features of automobile’s EE architecture, designing of power distribution unit becomes complex and challenging. Due to the increase in the number of features, the overall weight of power distribution unit increases and thereby affecting the overall system cost and fuel economy. The scope of this document is to scale down the weight and space of the power distribution unit without compromising with the current performance. The concept of next generation power distribution unit in automobiles is achieved using miniaturization of its sub-components which involves replacing the mini fuses and JCASE fuses with LP mini and LP JCASE fuses respectively. The transition doesn’t involve any tooling modification and hence saves the tooling cost. Furthermore, to address stringent weight and space targets, LP mini fuses and LP JCASE fuses were further replaced with micro-2 fuse and M-case fuse respectively. Similarly, Micro relay and Mini relay were replaced with Ultra micro and high current micro relay respectively. We took MPV segment vehicle for our initial testing and validation and it has been observed to have significant reduction in plastic weight and relay weight, which has consecutively led to significant overall cost reduction. Along with cost and weight, packaging space optimization is yet another advantage. This paper discusses the effectiveness of the latest technologies in the domain of power distribution system. These technologies have been validated and successfully implemented in several current platforms of Mahindra and Mahindra and have shown significant cost, weight and space benefits to the organization and thereby the same strategy is being deployed in new vehicle models as well.
D, Boobala KrishnanDua, HimanshiVijayan, TKirty, Apurbo
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