Wiring Harness News WHN Nov-Dec 2014

INDUSTRIAL INFO-TAINMENT s • Reality Check i : e Th su res • Global Aviation Technologies Is tu • Golden Rule for Customer Retention a • Continuous Improvement Goal for 2015 e F • Defining Reliability at Teledyne Oil & Gas, ODI Wiring Harness News NOVEMBER/DECEMBER 2012 1 • Wire Wisdom - Wire & Cable Cold Temperature Ratings NOVEMBER DECEMBER 2014 Global Aviation Technologies By Fred Noer _________________________________ f the many and varied com- panies in the wiring harness industry, Global Aviation Technologies (GAT) is one of the most unique. The multifaceted operation in Wichi- ta, Kan., provides products and services to companies, organizations, govern- ments and individuals in the United States and foreign countries that have business, commercial, military and per- sonal aircraft. GAT designs, engineers and manufactures wiring harnesses and electrical assemblies for systems and dis- plays primarily on small jets for busi- ness, charter and personal use. O The components and parts are for power distribution, communication, flight management, radar, navigation, instrument panels, interior lighting and entertainment systems in such aircraft as Bombardier (including the famous Lear- jet), Hawker, Beechcraft, Cessna and Gulfstream. GAT also installs equipment, does structural repairs and performs maintenance. GAT was founded in April 2002 by Woody Cottner, 55, vice president of business development. He shares owner- ship with his wife Candace, 51, director of operations. “Our company has made a living doing what the OEMs don’t want to do and from people who want to take care of legacy aircraft that are out of produc- Reality Check: How Three Common CFM Sensor Configurations Really Perform By Michael Reeves VP Business Development OES, Inc _________________________________ illions of wire terminal crimps are produced every day for the automotive, appliance, aerospace, and electronics industries. These wire terminal crimps are made by a wide range of processes and with a vast array of terminal and wire combinations. Crimp force moni- tors (CFM’s) are widely used in these production processes for the assurance of crimp quality and to eliminate the risk of supplying defective product into the supply chain. M CFM’s monitor every wire terminal crimp by using complex mathematical algorithms to discriminate between good and defective crimps. Many informative articles have been written about CFM’s – how they work, their per- formance, capability, and best practices to ensure these mission-critical monitor- ing systems function at top perform- ance. This article is focused on an over looked component of the CFM system - the force sensor. The force sensor provides the raw signal to the CFM and is one of the key components that determine the capabil- ity of the CFM system to discriminate ________________Continued on page 14 GAT provides maintenance for a A Hawker 4000. tion,” Woody Cottner said. “Our work includes things for supplemental type certificates issued by the Federal Avia- tion Administration.” The certificate means a plane can be modified from its original design. Cottner noted a customer may spend $3-5 million on upgrading the cockpit, interior, avionics package and paint of a plane. While that is a considerable expenditure, he stated a new Learjet costs $17-23 million. And, the modifica- tions are good for 10-15 years. GAT has 20 customers. Its first was Walmart with its Learjet fleet, which GAT still services. Other clients are BJets, Hiller and Bombardier in Wichita, Skyservice in Canada and Piedmont Air- lines in Salisbury, Md. One of the simplest GAT harnesses is produced for ASI in Wichita. The three- foot harness with five wires in a sleeve has a connector attached to the bottom of a seat in a Boeing 747 commercial air- liner. A complex harness is made to run from nose to tail on a Beechjet 400 busi- ness jet for its avionics. “That is a very intense harness,” Cottner said. “It has lots of wires, with the trunk six to eight inch- es in diameter. There are 20 to 25 con- nectors in the nose alone.” Printed circuit boards and electro- mechanical assemblies also are pro- duced by GAT to be used in conjunction with the harnesses or in converter boxes. An example of the latter is to con- vert autopilot from analog to digital. Because of the degree of specializa- tion at GAT, most of the harnesses are one off – the prototype and final prod- uct being one in the same. As a result, ________________Continued on page 38 Defining Reliability at Teledyne Oil & Gas, ODI By Joe Tito Wiring Harness News _________________________________ recently had the honor of touring the Teledyne Oil & Gas (TOG) ODI facility in Daytona Beach, FL. John Flynn, Vice President of Global Mar- keting, was kind enough to show me around, discuss their product line; and educate me on the unique reliability challenges in their industry. TOG is an alliance of Teledyne com- panies developing and producing high- reliability interconnect systems in sup- port of subsea oil and gas exploration and production. The ODI facility special- izes in subsea power and broadband data transmission. When we think of an oil platform, we generally think of the iconic rig on the ocean surface. But that’s only a small portion of what’s real- I ly going on. For every rig, there is a labyrinth of subsea pumps, power/data hubs, pressure/ temperature sensors, corrosion monitors, etc., that are doing most of the work (See Fig. 1, Page 28). These undersea processing facilities can span miles and connect multiple well heads. Assemblies produced at ODI sup- ply power and data to connect these elaborate systems. To augment their existing100,000 sq. ft. ODI manufacturing facility in Day- tona, TOG recently completed a 52,000 sq. ft. Technology Center to develop and test interconnect technologies in sup- port of offshore oil and gas production. The manufacturing facility is a 95% ver- tically integrated center with state-of- the-art injection molding, CNC machin- ing, clean assembly, and full testing capa- ________________Continued on page 28