Spreadsheet-based thermal analysis tools have been developed to analyze current carrying capacity of wire bundle configurations. Wire bundles composed of up to 50 elements may be solved within the spreadsheet tool itself. Larger bundles, composed of up to 150 elements, utilize a spreadsheet-based complex wire bundle thermal model builder where user inputs are processed into a thermal network model and output in the System Improved Numerical Differencing Analyzer (SINDA) format for solution. The resulting models include the effects of temperature varying resistance, wire gauge, insulation jacket properties, external radiation and convection, wire-to-wire thermal contact, radiation, and air conduction. Current procedures using published standards limit the types of configurations that can be assessed using graphical data. The goal of this effort is to provide analysis capability allowing assessment of a variety of configurations including bundles with internal smart shorts, combinations of wire gauges, and external jacket properties. Monte Carlo-based analysis capability is included in the tools and allows analysts to explore the solution sensitivity to uncertainties in a variety of input variables. Accurate thermal modeling of wire bundles ensures the design is robust against smart shorts within the wire bundle. Additionally, a model-based approach may allow for design efficiencies resulting in reduced wire bundle weight within an aerospace vehicle.
For more information, contact Steven Rickman, JSC, steven.l.rickman@nasa.gov