NCMS Project #: 140328
Problem: Wiring systems are the conduit that supports vital functions such as electrical power, control signal, and information distribution throughout a system. The wiring system is also the infrastructure linking electrical, electromechanical and electronics subsystems. Wiring has emerged as a critical system due to its increasing complexity, high-density, and critical communications interface.
The aging effects experienced by wiring systems include the accumulated damage from exposure to chemical, thermal, electrical, and mechanical stresses over time. However, the operational environment, installation, and maintenance practices often induce failure mechanisms as well. Wiring failures often appear as broken conductors, failed connector interfaces and damaged insulation, which can disrupt electrical signals, cause short circuits or lead to arcing.
- EA-6B – 6,646 circuit breakers were tested during the program, the majority of which tested good and not replaced, resulting in cost avoidance of $823,885.
- The C-2 Service Life Extension Program (SLEP) –
of rewiring the entire aircraft utilized the EWIS to verify the engineering data developed; verify the rewire installation was correct; and verified the workmanship of the installation. Costs were avoided in all three phases by reducing risk and finding problems at the earliest possible time.
- C-2A REWIRE PROGRAM – Validated the engineering documentation; seven engineering errors discover and corrected; additional engineering changes identified and made prior to termination of wiring effort. Estimated Savings: 24 to 40 man-hours per wiring error: some 240 man-hours total; $8,200 to $12,000 saved per aircraft.
- Portsmouth Naval Shipyard – Dockside Cranes:
EWIS was successful in establishing a baseline for future inspection test comparisons. Interruptions during a submarine overhaul can be avoided which cost as much as $60,000 per day until the problem is rectified.
- The USMC CH-46 helicopter ALQ-157 infrared countermeasures set used the EWIS to reduce test time on the infrared countermeasures harness from two hours to 20 minutes, including the setup time.
- Tobyhanna AD – The initial success of EWIS tools has prompted the procurement of six more ESP+ SWR meters by the Army. The Tobyhanna EWIS team is also looking into the development of a test program set for the AN/TSC-100 SATCOM Terminal. Mobile Support Multiplexer backplane tested by hand prior to test set requiring three days troubleshooting: Current set up time one hour, run time 20 minutes; Estimated saving on single wire problem 22 man-hours; also, the ESP+ meters reduced coaxial cable troubleshooting effort by up to 50%, some 30 to 35 fewer hours per shelter saving is approximately $3,500 per shelter.
Solution/Approach: The EWIS technology is being purchased and has migrated to multiple platforms throughout the Navy, Air Force, Army, and Marines. The following DoD organizations are the original participants and are using the EWIS Technology:
- Air Force (OO-ALC, F-16)
- Navy (NADEP Jacksonville)
- Navy (Portsmouth Naval Shipyard)
- Navy (NADEP North Island, San Diego)
- Army (Tobyhanna Army Depot)
Continuing/follow-on efforts are being pursued by the organizations.
Impact on Warfighter: The overall impact of the EWIS effort is reduced repair cycle times, more reliable repairs resulting in increased materiel up-time, and reduced cost to the using depot organizations.
- U.S. Navy (NADEP Jacksonville, EA-6B & S-3
- U.S. Air Force (OO-ALC, F-16)
- U.S. Navy (Portsmouth, Shipyard Cranes)
- U.S. Navy (NADEP North Island, C-2A)
- U.S. Army (Tobyhanna, Mobil Shelters)
- Eclypse International
- Sikorsky Aircraft