N093-176 TITLE: Wire Restraint Devices

TECHNOLOGY AREAS: Air Platform, Electronics, Weapons

ACQUISITION PROGRAM: PMA-261, H-53 Heavy Lift Helicopters Program

OBJECTIVE: Develop innovative wire restraint concepts to replace existing tying tape (tie string) and plastic cable tie straps (zip ties).

DESCRIPTION: Wiring restraint devices are used on all DOD aircraft. Existing restraint methods are limited to flexible glass, polyester tying tape or plastic cable straps. Failure of plastic cable straps is common, reducing physical support for the wiring system, exposing wire bundles to excessive movement and potential damage, and creating a potential hazard for foreign object damage (FOD) inside the airframe. Tying tape is preferred due to the limitations of plastic cable straps including their ability to function in high-temperature and high-vibration locations; effects of their exposure to ultra-violet light; strap failures that would cause the restraint to foul mechanical linkages or fall into mechanical parts; and material degradation in severe wind and moisture problem locations (wheel wells, wing folds, and other areas exposed to the environment). However, the preferred tying tape is labor intensive, requires greater skill to properly install and is difficult to install in tight places.

New freestanding wire restraint concepts should be capable of operating in high-temperature and high-vibration locations; not be affected by exposure to ultra-violet light; be easily and quickly installed in tight locations; and operate in severe wind and moisture problem locations (wheel wells, wing folds, and other areas exposed to the environment). Restraint performance should meet or exceed the elongation, breaking strength and slip resistance of finish C for tying tape or type 1 for plastic straps. If an install tool is necessary, it should be similar in size to existing cable strap install tools. New and existing materials will be considered.

PHASE I: Develop a suitable approach for durable, easy-to-install wiring restraint devices. Validate the approach analytically and provide simulation or modeling test data that would validate the approach.

PHASE II: Design, develop, and demonstrate wiring restraint device technology taking into account the aging characteristics of the material and damage potential to wire insulation over time under vibration. Conduct testing to demonstrate capabilities.

PHASE III: Prepare wiring restraint device samples for qualification testing and submit to qualifying activity. Transition the technology to air vehicle prime manufaturers.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: The currently available wiring restraint devices are used both in commercial and military aviation. The issues of lacing tape and plastic cable straps are common to both the commercial and military sectors. In addition, ships, submarines, and other applications using aerospace type wiring restraint devices have the same wiring chafing issues related to wiring restraint devices.

REFERENCES:
1. Cynthia Furse and Randy Haupt, "Down to the Wire," Utah State University

2. Preempting Aircraft Wiring Failures, AFRL Information Directorate, Information Technology Division, Dynamic Command and Control Branch, Rome, NY

3. Testimony of Bernard Loeb, Director Office of Aviation Safety, NTSB, regarding Aging Aircraft Wiring, September 15, 1999

KEYWORDS: Wiring; Restraint Devices; Plastic Cable Straps; Lacing Tape; Aircraft and Electrical; Zip Tie

** TOPIC AUTHOR (TPOC) **

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