Fast, Modular Wire Simulation

Tools to Better Understand

Small Wire Faults
Dr. Cynthia Furse, Brian Jones, Dr.Chit Lo, Eric Lundquist, Dr.
Kevin Wheeler, Shang Wu
University of Utah / LiveWire Test Labs / Utah State University/
NASA AMES Research Center
The Problem
http://www.ksc.nasa.gov/shuttle/missions/sts-67/
images/medium/KSC-95EC-0396.jpg
STS-93 Main Engine Controll
Space Shuttle Columbia
Probable Cause: Mechanical Damage during
maintenance that went undetected until an arc event
during launch.
The Aging Wire Problem
The polymer, Polyimide (Poly-X, Kapton, Stilan, Tefzel)
-- chosen because it was a light weight insulator --
breaks down with time
What Causes Wiring Faults?
Insulation failure
3%
Loose connection
2%
Short circuit
unspecified cause
(includes arcing
incidents)
3%
Chafed wire insulation
leading to short
circuit and/or arcing
31%
Other
19%
Broken Wires
11%
Unspecified Failure
6%
Short due to
corrosion
1%
Connector Failure
9%
Failure due to
corrosion
7%
Miswire
8%
Source: Navy Safety Center Hazardous Incident Data
Reflectometry Locates Faults
Time delay between Incident
and Reflected Pulses tells
distance to fault.
Incident Pulse sent down wire Reflected Pulse comes back
Time delay
Types of Reflectometry
Time Domain Reflectometry (TDR)
Frequency Domain Reflectometry (FDR)
Spectral Time Domain Reflectometry (STDR)
Spread Spectrum Time Domain
Reflectometry (SSTDR)
More
Correlation Tells Time Shift Between Two
Signals
Incident Signal
Reflected Signal
Time Shift
Correlation SHIFTS the signals. Multiplies ( x ) them.
Integrates ( + ) them.
Distance to Fault (meters) = Time Shift (s) x Velocity (m/s)
STDR:
Pseudo Noise (PN)
Code

PN
Code
known
time
shift
PN Code
unknown
time shift
Spectral Time Domain Reflectometry:
STDR

Modulated
PN code
with known
time shift
Modulated
PN code
with
unknown
time shift
Spread Spectrum TDR: SSTDR
MilStd 1553 Plus SSTDR
Peaks Show Fault
Location of Fault
But What About Small Faults?
Radial Cracks and Chafes Produce Small Reflections
Small Fault Small Reflection
Time delay between Incident
and Reflected Pulses tells
distance to fault.
Incident Pulse sent down wire Reflected Pulse comes back
Time delay
Load impedances from 20 to 2k ohms
Load impedances near 50 ohms
Attenuation Reduces Reflection
(frequency dependent)
SSTDR
40 ft
Attenuation
How LOW Can You Go??
Wire Fault Location
Reflectometry Can Find Faults Dead or Live
(Opens/Shorts)
Finding Small Faults (environmental effects
limit detectibility)
Simulating the System
Damaged Shield Model (promising)
Predict characteristic
Impedance (FDFD, CST)
Forward
Response
Experimental
Simulated
Twisted
Shielded
Pair
Wire
TDR SSTDR FDR
GBD or ABCD
?
Simulating Wire Faults
Inversion
(Fault Detection
or Location)
Analytical
Predict characteristic
Impedance (FDFD, CST)
Forward
Response
Experimental
Simulated
Twisted
Shielded
Pair
Wire
TDR SSTDR FDR
GBD or ABCD
?
Simulating Wire Faults
Inversion
(Fault Detection
or Location)
Analytical
Modular Simulation
Combinations of wire segments
Different Lengths and Impedances
Ideal for Combining Good and Bad Wires
Must be Frequency Dependent
Simulate OR Measure Individually
S
12
S
21
S
22
S
11
Combine
S
12
S
21
S
22
S
11
T

Modular Methods Tested

Time Domain (Generalized Bounce Diagram
(GBD), FDTD)
Frequency Domain (S-parameters, Signal
Flow Diagrams, ABCD, modified ABCD)
ABCD Network Model
S
Parameters
ABCD
ABCD ABCD
1
2 3
ABCD = ABCD1 x ABCD2 x ABCD3
ABCD S-Parameters = (reflection and
transmission coefficients)
Repeat for All Frequencies IFFT to Time Domain
Sample Results
0 5 10 15 20 25 30
-0.5
0
0.5
1
1.5
Length(m)
M
a
g
n
i
t
u
d
e
L=[3.68, 2.2, 2.77, 3], Z=[50,93,75,50], Load=47pF


Measured
Simulated - Perfect Step Source
Simulated - Measured Step Source
Figure 52 A Two-Section Example
TDR
RG58A/U RG59B/U RG62/U
2.77m 3.68m 2.2m
RG58A/U
3m
C=47pF
TDR
RG58A/U RG59B/U RG62/U
2.77m 3.68m 2.2m
RG58A/U
3m
C=47pF
ABCD Network Model
S
Parameters
ABCD
ABCD ABCD
1
2 3
Can Be Adapted to Branched Networks
Modified ABCD Very Fast and Efficient
1 1
1 1
A B
C D
(
(

1
V
1
I
2 2
2 2
A B
C D
(
(

2
V
2
I
3
V
3
I
n n
n n
A B
C D
(
(

n
V
n
I
1 n
V
+
1 n
I
+
L
L
A B
C D
(
(

1
V
1
I
1 n
V
+
1 n
I
+
1 1 2 2
1 1 2 2
where ...
n n
n n
A B A B A B A B
C D C D C D C D
( ( ( (
=
( ( ( (

3 3
3 3
A B
C D
(
(

2 2
2 2
A B
C D
(
(

1 1
1 1
A B
C D
(
(

1
V
1
I
L
Z
2
V
2
I
3
V
3
I
1 1
1 1
A B
C D
(
(

1
V
1
I
shunt
1 0
1/ 1 Z
(
(

2
V
2
I
3
V
3
I
3 3
3 3
A B
C D
(
(

1 1
1 1
A B
C D
(
(

1
V
1
I
2
V
2
I
2 2
2 2
A B
C D
(
(

A B
C D
(
(

1
V
1
I
2
V
2
I
Generalized Bounce Diagram
Simulate or Measure Single Sections
a
1
b
1
a
2
b
2
a
3
b
3
a
4
b
4
Generalized Bounce Diagram
Combine Transmissions and
Reflections
a
1
b
1
a
2
b
2
a
3
b
3
a
4
b
4
0 0 1 0 0 0 0 0
0 0 0 0 1 0 0 1
1 0 0 0 0 0 0 0
0 0 0 0 1 0 0 0
0 1 0 1 0 0 0 0
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
0 1 0 0 0 0 0 0
C
A
(
(
(
(
(
(
=
(
(
(
(
(
(

Module 1
(10 feet)
Module 2
(Fault)
Module 3
(7 feet)
Module 4
(3 feet)
Module 5
(light bulb)
Module 6
(5 feet)
Module 7
(fan)
1
2
3
4
5
6
7
8
9
10
13
14
11
12
R3
R4
R1
R2
R5
R6
R7
R8
R9
R10
R11
R12
R13
R14
Power
Source
Fault
Light
Bulb
10 feet
fan
7 feet
3 feet
5 feet
Can Do Branched Networks
a
1
b
1
a
2
b
2
a
3
b
3
a
4
b
4
0 0 1 0 0 0 0 0
0 0 0 0 1 0 0 1
1 0 0 0 0 0 0 0
0 0 0 0 1 0 0 0
0 1 0 1 0 0 0 0
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
0 1 0 0 0 0 0 0
C
A
(
(
(
(
(
(
=
(
(
(
(
(
(

2 1 row or column of
2 row or column of
n C
n C
a n A
b n A
=
=
Predict characteristic
Impedance (FDFD, CST)
Forward
Response
Experimental
Simulated
Twisted
Shielded
Pair
Wire
TDR SSTDR FDR
GBD or ABCD
?
GBD or ABCD provide Fast Time Domain Model
Inversion
(Fault Detection
or Location)
Analytical
Predict characteristic
Impedance (FDFD, CST)
Forward
Response
Experimental
Simulated
Twisted
Shielded
Pair
Wire
TDR SSTDR FDR
GBD or ABCD
?
Simulating Wire Faults
Inversion
(Fault Detection
or Location)
Analytical
Simulating Small Faults
2D FDFD 3D FDFD or FEM
Calculating Impedance
Cross-section of wire obeys Laplaces equation
Numerical equation obtained using central
difference method.
This equation is iteratively solved for potential
distribution.
Reference
Wire
Test
Wire
Electric Potential Distribution
Reference
Wire
Test
Wire
Electric Potential Distribution
The Insulation is electrically similar to air, and has
Very LITTLE effect on Electric Fields
Removing Insulation has LITTLE Effect on Fields
I nsulat ion damaged on side I nsulat ion damaged on t op
Radial crack
I nsulat ion damaged on t op
Conduct or visible but not damaged
Magnitude of Reflection
Open and Short Make Large Reflections
Damage to Insulation gives SMALL Reflection
Magnitude of Reflection
Damaging the Conductor Doesnt
Even Make Much Difference
(IF it isnt touching other Metal)
Magnitude of Reflection
Putting Water On/Near the
Wire DOES matter
Uncontrolled Impedance Wires
Effect of Uncontrolled Impedance
Vop = 0.594-0.602c
Controlled Impedance
UnControlled Impedance
Magnitude of Reflection
Moving the Wire
Matters Even More
Magnitude of Reflection
To Prevent False Positives Hardware Must be
Set BELOW Normal Variation
Radial Crack: Why Such a Small Reflection
What About Chafes?
For Practical Applications, Environment Limits Detection
Chafe Detection False Positives
What About Twisted Shielded Pair?
Damaged Shield Model
Fields leak out of shield
Can We Detect These Fields?
3D CST Simulations
Damaged Shield
Field Pattern
Potential Measurement System
Receive fields on the outside of shield
Measurement Example
H Probe
E Probe
Damaged Shield
Example Results
Consistent with expected distance.
Remaining challenge: Inversion
-20 -15 -10 -5 0 5 10 15 20
-1
-0.8
-0.6
-0.4
-0.2
0
0.2
0.4
0.6
0.8
1
Total length 11.28m, Fault at 8.68m
Distance (m)
R
e
l
a
t
i
v
e

A
m
p
l
i
t
u
d
e


Direct contact
E-Probe
H-Probe
11.28m
2.6m
2.6m
8.68m
The Role of Bandwidth
Higher bandwidth
Greater spatial resolution (see smaller length
faults, better resolution of the ones you do see)
Greater loss of high frequencies on the cable
(CABLE limits the possible bandwidth, longer
cables have more loss)
Bandwidth (and specific bands) must be chosen
so as not to interfere / be interfered with existing
signals
Types of Reflectometry
Time Domain Reflectometry (TDR)
Frequency Domain Reflectometry (FDR)
Spectral Time Domain Reflectometry (STDR)
Spread Spectrum Time Domain
Reflectometry (SSTDR)
More
Bandwidth: For TDR
time
frequency
TDR Pulse
time
frequency
A
1/A
A
1/A
Spread Spectrum
Time
Energy
Time
Energy
Narrow Time Broader Band
Broad Time Spread over broad frequency band
TDR
STDR
Attenuation Reduces Reflection
(frequency dependent)
SSTDR
40 ft
Attenuation
Higher Frequency (Bandwidth) =
Better Fault Resolution, Shorter Distance
MilStd 1553 Plus SSTDR
Cannot Interfere With Existing Signals
Reflectometry Can Find Faults Dead or Live
(Opens/Shorts)
Finding Small Faults (environmental effects
limit detectability)
Simulating the System
Damaged Shield Model (promising)
Wire Fault Location
What Next?
Advanced Interpretation Algorithms
Alternative Reflectometry Methods
Acousto-Optical Correlation
..

Noise
with
known
time
shift
Noise
with
unknown
time shift
Noise Domain Reflectometry (NDR)
NDR:
Advantages:
More flexible test method
May utilize existing signals (communication
over power line, etc.)
May provide multi-use of communication
system and testing of the wires in that
communication system.
Disadvantages:
SNR not as good as S/SSTDR (requires
longer test / averaging time)
Electrical Correlation Today
Slow, one delay
integrated at a time
A
B
Acousto-Optical Correlation:
Parallel Integration
Acousto-Optic Device
Example of AO Deflector
(Courtesy of Crystal
Technology)
Sound field inside
typical AO device
|
|
.
|

\
|
= |
.
|

\
|
=

l
a a
B
nv
c
K
k

2
sin
2
sin
1 1
Detect
Location of
Diffracted
Beam
(lens/CCD)
Acousto Optic Correlator
Acousto-optic Interaction
Light source
At Bragg
angle
Transducer with PN
code modulation
Principal
diffracted
beam
Detected with
An Imaging
Lens and
CCD
Undiffracted
beam
Individual delays
implemented in
parallel
1

3
Example Measured CCD Output
CCD Pixel #
Magnitude
Distance to Fault
0
50
100
150
200
250
300
350
400
450
500
0 100 200 300 400 500 600 700
length of the wire (ft)
p
e
a
k

p
o
s
i
t
i
o
n

(
p
i
x
e
Reflectometry Can Find Faults Dead or Live
(Opens/Shorts)
Finding Small Faults (environmental effects
limit detectibility)
Simulating the System
Damaged Shield Model (promising)
In the Future .
Advanced Interpretive Algorithms (Inversion)
Acousto-Optic Correlator (speed and power)
Wire Fault Location
Thank you to NASA AMES
Research Center for
Sponsoring this Research
Questions?
Dr. Cynthia Furse
cfurse@ece.utah.edu