AVT 4232:

ELECTROMECHANICAL
HARNESSING
Prepared by:
Aque, Gabriel Lloyd V.
148794-AMS
What is the importance of EWIS?
• Safety: The EWIS is critical for the safety of the aircraft. If the
EWIS fails, it can lead to a catastrophic accident.
• Reliability: The EWIS must be reliable and able to withstand
the harsh conditions of the aviation environment.
• Weight: The EWIS is one of the heaviest components in an
aircraft, so it is important to keep it as lightweight as
possible.
• Cost: The EWIS is also one of the most expensive
components in an aircraft, so it is important to design and
maintain it efficiently.
EWIS BEST PRACTICES
Design
• Use qualified personnel: The design of EWIS should be undertaken by qualified
personnel with the necessary expertise in electrical engineering and aviation.
• Follow industry standards: Design EWIS according to relevant industry standards and
regulations, such as those set by the Federal Aviation Administration (FAA) or the
European Aviation Safety Agency (EASA).
• Consider safety and reliability: Prioritize safety and reliability in the design process.
Use high-quality materials, employ appropriate insulation and protection for wires
and cables, and implement redundancy measures to prevent single-point failures.
• Minimize weight and cost: Optimize the EWIS design to minimize weight and cost
without compromising safety or reliability. Consider using lighter-gauge wires,
bundling wires effectively, and using standardized components.
 EWIS BEST PRACTICES
MAINTENANCE
• Regular inspections: Establish a regular inspection schedule for EWIS
components, including visual inspections, insulation checks, and connection
integrity assessments.
• Proactive maintenance: Address identified issues promptly and proactively to
prevent further damage or potential failures.
• Proper documentation: Maintain accurate and up-to-date records of EWIS
maintenance activities, including inspection reports, repair records, and
modification documentation.
• Training and awareness: Train maintenance personnel on EWIS best practices
and ensure they are aware of potential hazards and proper handling
techniques.
EWIS BEST PRACTICES
MODIFICATION
• Authorization and documentation: Obtain proper authorization before
modifying EWIS components. Document all modifications clearly and include
them in the EWIS maintenance records.
• Impact assessment: Carefully assess the impact of any proposed
modifications on the overall EWIS design and its interactions with other
systems.
• Compatibility: Ensure that any replacement components are compatible with
the existing EWIS and meet the required specifications.
• Testing and validation: Thoroughly test and validate any modified EWIS
components or configurations before returning them to service.
EWIS Investigation

Electrical Wiring Interconnect System

(EWIS) wiring investigations are crucial for
identifying and addressing electrical
faults or anomalies that could
compromise the safety and reliability of
an aircraft. These investigations involve a
systematic approach to gather
information, analyze data, and
determine the root cause of the issue.
EWIS Investigation

The primary objectives of an EWIS wiring

investigation are to:
• Identify the nature and extent of the
wiring fault or anomaly.
• Determine the root cause of the fault
or anomaly.
• Develop corrective actions to prevent
future occurrences.
• Document the investigation findings
and recommendations.
 EWIS Investigation
An EWIS wiring investigation typically consists of the following phases:

Information Gathering:
• Review aircraft maintenance records, logs, and technical documentation to
gather relevant history.
• Interview aircraft operators, maintenance personnel, and any witnesses to the
incident or anomaly.
• Gather visual evidence, such as photographs, videos, or sketches, of the
affected area.
Site Inspection:
• Conduct a thorough visual inspection of the affected wiring, paying close
attention to signs of damage, corrosion, insulation breaks, or improper routing.
• Utilize specialized tools, such as continuity testers, insulation testers, and
infrared cameras, to assess the condition of the wiring.
• Document the findings of the site inspection, including detailed observations,
measurements, and sketches.
EWIS Investigation
Analysis and Root Cause Determination:
• Analyze the gathered information, inspection findings, and test results to
identify patterns, potential causes, and contributing factors.
• Consider the aircraft's operating environment, maintenance history, and any
known design or manufacturing issues that could have contributed to the fault
or anomaly.
• Utilize knowledge of electrical engineering, aviation systems, and failure
analysis techniques to determine the root cause of the issue.

Corrective Actions and Recommendations:

• Develop a plan of corrective actions to address the identified root cause and
prevent future occurrences.
• Recommend modifications to maintenance procedures, training programs, or
design specifications to enhance EWIS integrity and reliability.
• Communicate the investigation findings, corrective actions, and
recommendations to relevant stakeholders, including aircraft operators,
maintenance personnel, and regulatory authorities.
 EWIS Investigation
Documentation and Reporting:

• Prepare a comprehensive investigation report that details the entire process,

including information gathering, site inspection, analysis, corrective actions,
and recommendations.
• Include supporting documentation, such as photographs, sketches, test results,
and maintenance records.
• Ensure the investigation report is clear, concise, and easy to understand for all
stakeholders.

EWIS wiring investigations play a critical role in ensuring the safety and reliability
of aircraft electrical systems. By following a systematic approach to gather
information, analyze data, and determine the root cause of electrical faults or
anomalies, investigators can effectively address issues and prevent future
occurrences. Thorough documentation and reporting of investigation findings
are essential for knowledge sharing, continuous improvement, and regulatory
compliance.
AIRCRAFT WIRE DEGRADATION
AIRCRAFT WIRE
DEGRADATION

Aircraft wire degradation is a

critical issue that can significantly
impact the safety and reliability of
aircraft operations. Over time,
wires and cables within an
aircraft's electrical wiring
interconnect system (EWIS) can
deteriorate due to various factors,
leading to potential hazards such
as electrical shorts, fires, and
system malfunctions.
Factors Contributing to Aircraft Wire Degradation
Several factors contribute to aircraft wire degradation, including:
ENVIRONMENTAL FACTORS:
• Temperature extremes: Exposure to extreme temperatures, both hot
and cold, can cause the insulation on wires to crack or become
brittle, increasing the risk of insulation breaks and electrical shorts.
• Moisture and humidity: Prolonged exposure to moisture and humidity
can lead to corrosion of wire conductors and insulation breakdown,
potentially causing short circuits and ground faults.
• Vibration and mechanical stress: The constant vibration and
mechanical stress experienced during aircraft operation can cause
fatigue cracks in wires and connectors, leading to wire breakage
and electrical failures.
CHEMICAL FACTORS:
• Exposure to chemicals: Exposure to various chemicals, such as fuels, lubricants,
and cleaning agents, can degrade wire insulation and make it more susceptible
to damage.
• Off-gassing from materials: Certain materials used in aircraft interiors, such as
adhesives and sealants, can release gases that can cause degradation of wire
insulation over time.

ELECTRICAL FACTORS:
• Overloading: Overloading of circuits can cause excessive heat generation in
wires, leading to accelerated insulation degradation and potential failure.
• Electrical transients: Electrical transients, such as surges and spikes, can cause
damage to wire insulation and connectors, increasing the risk of electrical faults.
Consequences of Aircraft Wire Degradation

Aircraft wire degradation can have serious consequences, including:

• Electrical shorts: Electrical shorts can cause sudden surges of

current, potentially leading to fires, equipment damage, and loss of
control systems.

• Ground faults: Ground faults can cause erratic system behavior,

instrument malfunctions, and potential shocks to personnel.

• System malfunctions: Degraded wires can lead to intermittent

system malfunctions, affecting navigation, communication, and
other critical systems.
Mitigation Strategies for Aircraft Wire Degradation
To mitigate the risks associated with aircraft wire degradation, several
strategies can be implemented:
• Preventive maintenance: Regular inspections and maintenance of
the EWIS are crucial to identify and address early signs of wire
degradation before they lead to failures.
• Protective measures: Protective sleeving, shielding, and routing of
wires can help shield them from environmental hazards and
mechanical stress.
• Material selection: Choosing wires and cables with high-quality
insulation materials that can withstand the rigors of the aviation
environment is essential.
• Circuit protection: Overcurrent protection devices and transient
voltage suppression (TVS) devices can help prevent wire damage
caused by electrical overloads and surges.
Common Causes of Electrical Cable Failure
• Overload: When an electrical cable carries more current than it is designed to
handle, it can overheat, leading to insulation breakdown and potential fire
hazards. Overloading can occur due to excessive demand on the circuit or
faulty equipment.

• Mechanical Damage: Electrical cables are susceptible to mechanical

damage from various sources, such as bending, twisting, pulling, crushing, or
exposure to sharp objects. These damages can compromise the integrity of
the cable's insulation, leading to short circuits, ground faults, and complete
cable failure.

• Environmental Factors: Environmental factors, such as extreme temperatures,

moisture, UV radiation, and exposure to chemicals, can significantly degrade
the insulation of electrical cables over time. This degradation can lead to
insulation breakdown, conductor corrosion, and ultimately, cable failure.
• Ageing: Electrical cables have a finite lifespan, and over time, the
materials used in their construction can deteriorate. This ageing
process can lead to cracking, brittleness, and loss of insulation
integrity, increasing the risk of cable failure.

• Improper Installation: Improper installation practices, such as

incorrect routing, inadequate support, or loose connections, can
contribute to electrical cable failure. These issues can lead to stress
on the cable, insulation damage, and potential arcing or sparking.
END OF
PRESENTATION.
QUESTIONS?
REFERENCES:
• American Institute of Electrical Engineers. (2020). National Electrical Code 2020: NFPA 70. National Fire Protection Association.
• American National Standards Institute. (2023). ANSI/TIA 568.C.2-2023 Telecommunications Cabling Systems for Commercial
Buildings. American National Standards Institute.
• Electrical Safety Foundation International. (n.d.). Electrical Wire Degradation and Failure. Electrical Safety Foundation
International. Retrieved from https://www.esfi.org/
• Federal Aviation Administration. (2023). Advisory Circular 43-13-1B, Acceptable Methods, Techniques, and Practices (AMTP) for
Electrical Wiring Interconnect Systems (EWIS) Design, Development, and Installation. Federal Aviation Administration.
• Institute of Electrical and Electronics Engineers. (2016). IEEE Standard 574, Recommended Practice for Inspection and
Maintenance of Electrical Power Systems. Institute of Electrical and Electronics Engineers.
• International Electrotechnical Commission. (2017). IEC 60332-1-2:2017, Tests for Electric Cables and Flexible Cords - Part 1-2: Fire
Hazard Testing - Self-Propagating Combustion of Single Insulated Cables and Cords. International Electrotechnical Commission.
• National Fire Protection Association. (2023). NFPA 780: Standard for the Installation of Electrical Optical Fiber Cable (OFCP).
National Fire Protection Association.
• National Institute of Standards and Technology. (2023). NIST Guide for the Selection of Wire and Cable for Use in Buildings.
National Institute of Standards and Technology. Retrieved from https://govtribe.com/file/government-file/fa301619u0197-
attachment-4-690-iss-cabling-standards-2018-dot-pdf
• Underwriters Laboratories. (2023). UL 769 Standard for Wire and Cable Terminations for Use in Buildings. Underwriters
Laboratories.
Electromechanical Harnessing Required materials for laboratory activity (SECTION):
• Plywood 100 cm x 80 cm
• Electrical Wire 14 AWG - 3 meter per color (red, black, green, yellow, blue, white or gray)
• Nylon Cable Tie 11" (30 pcs per student)
• 20 Pcs Adjustable Cable Clamp
• 50 Wire Connectors (Male and Female)
• Wire Terminal Connectors
• 50 Heat Shrink Tube
• 5M Wire Organizer Wrap Tube
• Insulating Gloves
Optional:
• Wire Stripper (5 pcs provided by school)
• Wire Crimping Tool (5 pcs provided by school)