Active Reflection Cable Health Evaluation Recorder (ARCHER) for Monitoring of In-Service Steel Wire Cables

Dynovas' Active Reflection Cable Health Evaluation Recorder (ARCHER) posses a feasible, ergonomic and cost effective solution for monitoring, detection, and analysis of defects in steel wire cables utilized in Cross Deck Pendant applications. Providing detection capabilities over 360° around the cable surface for defects >0.04in. along cable lengths of over 100 feet in under 2 minutes. To accomplish this, the ARCHER will feature a two-piece lightweight and all-weather primary structure capable of withstanding harsh environmental conditions common along aircraft carrier flight decks. The device is capable of being affixed at any point along the length of an in-service or out-of-service CDP cable due to a two-piece rigid structure that is assembled in a clamshell configuration to accomplish either localized or full length scans. Through utilizing environmentally inert materials such as glass/polyethylene composite outer shells, marine epoxy/carbon composite frames, and compatible titanium or stainless-steel fittings in high-impact areas the ARCHER is designed to meet performance requirements specifically outlined in MIL-STD-810H. Additionally, the novel device architecture will contain a series of dynamic roller apertures providing local stabilization across the cable scanning area, as well as provide identification and evaluation of cable straightness, diameter and kinks/bends. These multi-petalled roller apertures are equipped with piezoelectric transducers along an axis of vertical travel perpendicular to the central axis of the ARCHER, and utilize compression springs to apply a known range of force against the piezo sensors to register the various motion/profile of the cable within the ARCHER unit as a scan is performed by providing distinct output voltage signals. Between the in- (FWD) and out-portals (AFT) of the ARCHER housing, exists the optical sensory array for detection and recording of defects providing a continuous 360° scan of CDPs. The data obtained by ARCHER’s internal sensor components will be subsequently fed into a central processing board utilizing a novel algorithm for interpretation of recorded data with outputs showing the continuous count and location of the number of wire breaks and or abnormalities identified during scanning. Internal LEDs will be utilized to maintain a constant light source for reflection-based imaging, enabling consistent performance in both day and night conditions. In addition to a visual representation of the defects, any identified abnormalities will be logged with relative distance to the scan’s starting point and photographed for further inspection by the operator if desired. The algorithm-interpreted results will be communicated through a graphic user interface (GUI) illustrating the number of broken wires that will indicate needed CDP replacement after four (4) broken wires are detected.