Fighter/EW/Helo/Patrol Arc Fault Circuit Breaker Development. April 2007
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1 Fighter/EW/Helo/Patrol Arc Fault Circuit Breaker Development April 2007 Sue Waggoner Naval Surface Warfare Center Crane (812)
2 What is the Arcing Fault Problem
3 Problem Description Thermal Circuit Breakers are not designed to detect arcing (sputtering) faults for aircraft to prevent electrical fires. Arcing faults are the predominate typed of fault on aircraft wiring and do lead to many maintenance actions and possibly fires such as Swissair 111. The FAA reports an average of 3 smoke in the aircraft events/day in the civilian aircraft fleet
4 Navy Problem Definition NALDA average annual incident rate of per aircraft type, 38 types of aircraft corresponds to an incident rate of 4841 per year. Naval Safety Center documented 30 In-flight Navy aircraft wiring fires which caused mission aborts. Existing thermal circuit breakers are not designed to detect arcing faults
5 Expected Payoffs AFCB protects/provides maintenance information on power wires (15-20% of system wiring) 1 to 2 million organizational man-hours per year are spent troubleshooting and repairing aircraft wiring. With respect to power wiring incidents, AFCB technology will reduce maintenance man-hours by 35% (70,000 hours) reduce mission aborts and NMC hours by 35% ($9M/year) AFCB will protect A/C wiring power system by detecting and isolating arcing fault which can cause smoke in the cockpit mission aborts and fires reduce in-flight electrical fires and subsequent loss of aircraft by 80% ($27.3M/year) Estimated savings of $37.5M per year after full implementation.
6 What Does An Arc Fault Current Waveform Look Like?
7 Fixed Wing AC Generator Dry Arc Condition F-18 AC 10 AWG 25 Amp (A) MIN Voltage, V Res: 6.667mV, 10µs Time, s 2:28:52 PM, 30 Jul 2002 c:\documents and settings\michael.t.allen\my documents\programs\afcb ground tests 2003\f18 afcb mar2003\ f18 ac 10 awg 25 amp 01.wft 600 F-18 AC 10 AWG 25 Amp (A) MIN Current, A Res: 33.33mA, 10µs Time, s 2:28:52 PM, 30 Jul 2002 c:\documents and settings\michael.t.allen\my documents\programs\afcb ground tests 2003\f18 afcb mar2003\ f18 ac 10 awg 25 amp 04.wft
8 Fixed Wing AC Generator Wet Arc 200 Condition F-18 AC 10 AWG 25 Amp (1) MIN, Drip Test Voltage, V Res: 16.67mV, 10µs Time, s 9:58:43 AM, 1 Nov 2002 c:\documents and settings\michael.t.allen\my documents\programs\afcb ground tests 2003\f18 afcb mar2003\ f18 ac 10 awg 25 amp drip 01.wft 800 F-18 AC 10 AWG 25 Amp (1) MIN, Drip Test Current, A Res: 33.33mA, 10µs Time, s 9:58:43 AM, 1 Nov 2002 c:\documents and settings\michael.t.allen\my documents\programs\afcb ground tests 2003\f18 afcb mar2003\ f18 ac 10 awg 25 amp drip 04.wft
9 Helo AC Generator Dry Arc Condition 250 H6 0 AFCB GEN 6 6 (V an) Vrms 100 Voltage, V Res: 8.333mV, 10µs Time, s 2:32:37 PM, 27 Aug 2003 c:\windows\desktop\michael allen\programs\h60 afcb gen aug2003\h60 afcb gen wft files cd1\h60 afcb gen66 _01.wft 800 H6 0 AFCB GEN 6 6 (Ia) Current, A Amps RMS Current 77 msec Res: 33.33mA, 10µs Time, s 2:32:37 PM, 27 Aug 2003 c:\windows\desktop\michael allen\programs\h60 afcb gen aug2003\h60 afcb gen wft files cd1\h60 afcb gen66 _04.wft
10 Helo AC Generator Wet Arc Condition H6 0 AFCB GEN 1 35 (V an) 52.3 Vrms Voltage, V Res: 8.333mV, 10µs Time, s 1:14:20 PM, 8 Sep 2003 c:\windows\desktop\michael allen\programs\h60 afcb gen aug2003\h60 afcb gen wft files cd3\h60 afcb gen135 _01.wft H6 0 AFCB GEN 1 35 (Ia) 258 Amps RMS Current 25 msec Current, A Res: 16.67mA, 10µs Time, s 1:14:20 PM, 8 Sep 2003 c:\windows\desktop\michael allen\programs\h60 afcb gen aug2003\h60 afcb gen wft files cd3\h60 afcb gen135 _04.wft
11 Helo AC Generator w/ 200 Amp T/R Dry Arc DC Condition H60 AFCB GEN 180 (V dc) Vdc Mean 29 Voltage, V Res: 1.667mV, 10µs Tim e, s 10:39:30 AM, 23 Sep 2003 c:\windows\desktop\michael allen\programs\h60 afcb gen aug2003\h60 afcb gen wft files cd4\h60 afcb gen180 _08.wft H60 A FCB GEN 180 (I dc Positive) Amps Mean Current, A Res: 29.17mA, 10µs Time, s 10:39:30 AM, 23 Sep 2003 c:\windows\desktop\michael allen\programs\h60 afcb gen aug2003\h60 afcb gen wft files cd4\h60 afcb gen180 _09.wft
12 What Is Being Developed And Tested?
13 Fiscal Year Arc Fault Circuit Breaker Developmental Timeline Transport Aircraft Development Lab Test Flight Install Tests Prod. ONR/FAA/AAIPT Component Impr Program Fighter/Helo/Patrol A/C Begin Devel Lab Test Ground Test Flight Test Prod.
14 Qualified for Commercial Transportation and Military-Commercial Derivatives Originally trying to get from household circuit breaker to a large MS24571 circuit breaker Industry fitted arc fault circuitry into a MS14105 and MS3320 AFCB - MS14105
15 AFCB Testing Defining Arcing Waveforms Defining Electrical Load Waveform EMI Testing Temperature Altitude Testing Vibration Testing Electrical Testing Flight Testing
16 Flight Tests NAVAIR C-9B 500 Flight Hours Six AFCB H Flight Hours Six AFCB F/A-18, H-60, P-3 Planned for FY07 FAA Boeing Flight Hours 20 AFCB Industry Boeing 767 Quantus Flight Hours
17 AFCB Transition Plan Transition for legacy aircraft through retro-fit on typical 30 month inspection phase Transition through retrofit or preferred spare part Transition Starts in FY07 depending upon company tooling capability Transition Platforms H-53 P-3C F/A-18 H-60 PMA-261 PMA-290 PMA-265 PMA-299
18 Project Highlights Arc Faults have been a constant problem for the past 10 years Timeline 6.3 development in FY02 ready for transition to E&MD in FY07 AFCB selected as part of the Core Program under FNC-TOC (6.3 funds) Cooperating with Air Force and FAA investigating the problems of arc faults in aging wiring systems with transition opportunities exist within Navy, other Government agencies, and industry
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