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Damage to First
Wire
Damage to Second
Wire
First Wire baseline
Second Wire
Baseline
FIGURE 11. WIRE INTERACTIONS IN GROUP I MIXED BUNDLES
17
Overall, the results indicated that within the subjectivity of the data, wire-to-wire wear is not
significant in mixed or nonmixed bundles on the wire types tested, with the possible exception of
XPI wire (code 3) that exhibited moderate wear in both the mixed and nonmixed bundles (see
figures 12 and 13). The vibration level chosen for the program is similar to the high vibration
levels expected in U.S. Navy aircraft, so it can be presumed that at lower levels, the wear would
be less. The vibration profile used in this test program may be different from the vibration levels
experienced by the EWIS in commercial aircraft.
FIGURE 12. MODERATE WIRE-TOWIRE
WEAR ON GROUP I XPI IN
BUNDLE MIXED WITH PTFE
FIGURE 13. MODERATE WIRE-TOWIRE
WEAR IN GROUP I NONMIXED
XPI BUNDLE
5.1.4 Wire Wear From Clamps.
The visual examination data from the unassembled bundles are also summarized in appendix C,
table C-6 so that the data regarding wire wear from the clamps for each wire type could be
analyzed. Each column in table C-6 provides a comparison of the nonmixed bundle to the mixed
bundle combinations selected. The table also indicates whether the bundle was slipping within
the cushion clamps after 100 hours of vibration, provides a damage rating for the wires rubbing
against the fixture plate, and quantifies the electrical failures.
The graphical representation of the wire wear from clamps in mixed and nonmixed conditions
for each wire type is shown in figures 1 through 10.
Figures 1, 4, and 5 show that only the PVC/glass/nylon, XLETFE, and XLETFE alloy wire types
(codes 1, 4, and 5, respectively) exhibited more wear from the clamps in certain mixed bundles
than in the nonmixed bundle. It was also noted that the XPI, PTFE, MF-PTFE, PTFE/glass,
PI/PTFE, and PI/PTFE alloy wires (codes 3, 6, 7, 9, 10, and 11) all exhibited moderate or severe
wear from the clamps, but the wear was similar in the mixed and nonmixed bundles (see figures
14 and 15 and additional figures D-1 through D-7 in appendix D).
The one XPI wire that failed the wet DWV test was determined to be from a combination of
wear from wire-to-wire interaction and wear from the clamps in the nonmixed bundle (see
figure 14).
18
FIGURE 14. MODERATE WIRE WEAR
FROM CLAMPS ON NONMIXED XPI
BUNDLE IN GROUP I
FIGURE 15. MODERATE WIRE WEAR
FROM CLAMP ON PI/PTFE AND
XPI IN GROUP I
The wire types with the most electrical failures were the PTFE/glass and PTFE (codes 9 and 6,
respectively); however, all the failures were attributed to the severe wear from the clamps (see
figures D-1, D-2, D-3, and D-5 in appendix D).
The PI/PTFE wire (code 10) exhibited one DWV failure in a bundle mixed with MF-PTFE
(code 7), which was attributed to moderate wear from the clamps (see appendix D, figure D-8)
and wear from the vibration fixture plate. No wire-to-wire wear was evident in the bundle.
Data was also plotted to analyze whether the clamp diameter and bundle diameter difference or
slippage in the clamps after 100 hours of vibration exposure had a direct correlation to the
severity of wire-to-wire or wire from clamp damage.
Figure 16 indicates that a higher difference between the bundle and clamp diameters was not the
only factor in determining the severity of the wire-to-wire wear. The figure also indicates that
slipping in the clamps did not cause the wire-to-wire damage to be more severe.
0
1
2
3
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07
Clamp and bundle diameter difference (in.) Severity of Damage
No slippage
Slipped
FIGURE 16. GROUP I: TIGHTNESS OF CLAMP VS WEAR FROM WIRE
19
Figure 17 indicates that a higher difference between the bundle and clamp diameters was not the
only factor in determining the severity of the wire wear from the clamps. The figure also
indicates that slipping in the clamps did not necessarily cause the wire wear from clamps to be
more severe.
0
1
2
3
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07
Clamp and bundle diameter difference (in.)
Severity of Damage
No slippage
Slipped
FIGURE 17. GROUP I: TIGHTNESS OF CLAMP VS WEAR FROM CLAMP
These results were not expected, since it is generally an industry standard practice to tightly
clamp wire bundles to minimize wire movement and wear from the clamps and other wires.
More investigation is needed to determine the appropriate level of clamping required to
minimize wire wear.
5.1.5 Wire Wear From Straps and Lacing String.
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