Public Funding for Axon Cable Limited

The AISA project advances the development of advanced active inlet systems, primarily focussed on the delivery of a smart, ice protected environmental control system scoop intake and actuated front flap FOD protection system. The project integrates a series of innovative technologies, including; smart controlled electro-thermal ice protection systems, passive acoustic abatement technology and advanced coating technologies, flexible wire harness assemblies and miniaturised connectors. The project also develops a high rate, highly productive manufacturing capability. The work packages will be developed by GKN Aerospace working in partnership with the University of Nottingham, Trackwise Designs and Axon Cable Ltd.

Ageing electrical wiring inspection is one of the concern in aerospace sector. Aircraft wires operate under constant change of operational conditions i.e. aircraft wires might operate under a cold, hot or humid environment with variations in the atmospheric pressure. Operating in such conditions might create chafes, cracks, cuts, delamination or embrittlement in the insulation of the aircraft wires. The extreme conditions under which aircraft wires operate may cause failure if it becomes brittle or cracked. In these scenerios aircraft wiring can be potential fire hazard. There have been 400 reported incidents due to aircraft wiring failures. Therefore, there is a need for an inspection technique to improve the reliability of the aircraft wiring. NDT technology can be used to inspect aircraft wires and is regarded as the promising technology for aerospace industry to reduce its maintenance costs by 70% and can increase the system lifetime operation of aerospace systems. Consequently,reducing the need for new products, which will ultimately save cost for aviation industry. UltraHandMan project will develop a novel portable wiring inspection system based on extended long range ultrasonic testing techniques ,advanced signal processing software, innovative sensor array in combination with energised handheld pulser/receiver. Flaws in the wiring will reflect ultrasound back to the sensor assembly and will be detected by the pulser/receiver.Insulation damage will be recognised by advanced signal processing and pattern recognition techniques.

The objectives of this project are to demonstrate the feasibility of using novel, lightweight, long-length, flexible printed circuitry to replace traditional wire and cable in aerospace applications and to demonstrate a cost effective reel-to reel manufacturing process for a system solution.

To develop and implement a predictive fatigue failure design methodology for complex cable structures to improve reliability.