Innovative Submersible Outboard Cable Failure Detection and Prediction Device
Navy SBIR 2010.1 - Topic N101-057
NAVSEA - Mr. Dean Putnam - [email protected]
Opens: December 10, 2009 - Closes: January 13, 2010

N101-057 TITLE: Innovative Submersible Outboard Cable Failure Detection and Prediction Device

TECHNOLOGY AREAS: Ground/Sea Vehicles

ACQUISITION PROGRAM: NAVSEA PMS435 - AN/BLQ-10 and PEOC4I PMW770 - Sub High Data Rate Antenna

OBJECTIVE: Develop a novel approach using innovative research and development to detect potential sources of failure in and evaluate the condition of multi-conductor (i.e., copper pins, copper coax, and fiber) cables.

DESCRIPTION: There are specialized outboard electrical cables which link masts or sensors to their outboard electrical hull fitting. These cables can vary in length and complexity within different applications and classes of submarines. Many programs use these specialized electrical outboard cables including Communications, Imaging, Electronic Warfare, and Sonar. These cables are used in other military and commercial applications as well. During operations, these outboard cables can develop kinks, fractures, or breaks in some of the conductors which eventually lead to system failure.

Currently, cables are checked only for continuity and resistance readings. This method does not detect whether any of the strands in a wire are broken; or whether a coaxial conductor is fractured. Broken strands in a wire could lead to cable failure in a matter of days, or weeks, depending on the severity of the wire fatigue. Unless the wire is completely broken, continuity may still be verified. There is currently no device capable of detecting potential failures and predicting the life expectancy of outboard cables that are day in and day out subjected to harsh environments. Periodic inspection of outboard multi-conductor cables with a means to identify potential failures will allow the Navy to predict the service life and replace cables before a complete open-circuit failure occurs during at-sea operations.

A non-destructive test set is desired, that shall be able to evaluate the health of, and pinpoint potential failures in any submerged cable (whether on a submarine or other submersible craft); including cables that may be exposed to extreme temperatures, high hydrostatic pressure, bending, or any other external force that may decrease the useful life of the cable. It is desired that this unit be handheld and that a single person be required for operation. It is also desired that the unit be ruggedized as its primary use will be at shipyards during installations and shipchecks prior to underway periods.

An example of the types of failures this device should detect and predict, are the failures being seen with the SubHDR Dip Loop cable. The SubHDR Dip Loop cable is an outboard electrical cable linking the Submarine High Data Rate mast to its electrical hull fitting. During operations, the SubHDR Dip Loop Cable develops z-kinks in some of the conductors which eventually lead to open � circuit breaks, and system failure. It is thought that conductor kinks occur during the operation of the mechanical handling system; however, the root cause has not been identified.

PHASE I: Conduct research to develop a novel approach to detect potential failures, particularly kinks, fractures, and breaks as well as predict life expectancy in outboard multi-conductor cables. Results from Phase I should include initial design schematics, preliminary control software and prediction algorithms, and anything else that would indicate the production of a prototype detection and prediction device during Phase II is feasible.

PHASE II: Based on the outcome of the Phase I effort, develop a scaled prototype to be evaluated within a controlled environment to detect and predict outboard cable failures. The prototype should be able to evaluate new multi-conductor cables for quality control as well as inspect existing cables for fatigue from use. The prototype should also be able to demonstrate its predictive algorithms used for service life estimates.

PHASE III: Upon successful completion of the Phase II effort the program office anticipates working with the firm and its manufacturers in order to procure a full scale prototype for real world testing within a shipyard environment. Once the R&D efforts have been completed the program office anticipates purchasing units for use within the Navy.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: Other potential applications include other branches of DOD with in service multi-conductor cables, commercial industries such as telecom, and automated systems using multi-conductor cables.

REFERENCES:
1. Sub-cycle detection of incipient cable splice faults to prevent cable damage; Kojovic, L.A.; Williams, C.W., Jr.; Power Engineering Society Summer Meeting, 2000. IEEE Volume 2, 16-20 July 2000

2. Application of thermoelectric aging models to polymeric insulation in cable geometry; Cooper, E.S.; Dissado, L.A.; Fothergill, J.C.; Dielectrics and Electrical Insulation, IEEE Transactions on [see also Electrical Insulation, IEEE Transactions on] Volume 12, Issue 1, Feb. 2005

KEYWORDS: SubHDR; Dip Loop; Cable; outboard; break; z-kink; multi-conductor

** TOPIC AUTHOR (TPOC) **
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