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Japanese Probe Finds Miswiring of Boeing 787 Battery
NeverVotedBush writes in with the latest installment of the Dreamliner: Boeing 787 saga. "A probe into the overheating of a lithium ion battery in an All Nippon Airways Boeing 787 that made an emergency landing found it was improperly wired, Japan's Transport Ministry said Wednesday. The Transport Safety Board said in a report that the battery for the aircraft's auxiliary power unit was incorrectly connected to the main battery that overheated, although a protective valve would have prevented power from the auxiliary unit from causing damage. Flickering of the plane's tail and wing lights after it landed and the fact the main battery was switched off led the investigators to conclude there was an abnormal current traveling from the auxiliary power unit due to miswiring."
When I read of it, I felt more vindicated than surprised.
During my tenure in aerospace, I had witnessed more and more of a disregard for detail work. What used to be a good thing called "attention to detail" started being regarded negatively as "being a perfectionist".
The devil is in the details. Thousands of things work perfectly. One does not. This is the inevitable result of overlooking just one detail.
"Prove all things; hold fast that which is good." [KJV: I Thessalonians 5:21]
Yes, and it's extremely annoying if you want to do anything to your own car. It's bad on the same level as proprietary connectors for phones and all that, but unfortunately the amount of people improving their own cars is too low to cause any consumer feedback to manufacturers.
And I don't mean adding stupid spoilers and boost chips and sillyness, I mean stuff like adding an extra pair of high beams that can be operated with the same button as the regular high beams. That will take some serious hacking on a modern car. If car manufacturers were good at making things, this wouldn't be a huge problem, but modern cars do so many things wrong that it's infuriating. Like putting lambertian leds in places where they should have put batwing ones, forcing me to put a diffuser in front of it so that my daughter is able to sleep in her car seat. Or making it a fifteen-minute job to remove the battery for charging it during the winter, when it should take two minutes. Or putting the light that activates when you open the trunk in the far left corner of the trunk, so that it doesn't light up anything if you actually have something in the trunk. I could go on about this for a while...
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a wiring problem could be as simple as using an incorrect thermistor on a Li-ion pack or not wiring a thermistor in at all. These are often used to alter charge/discharge rates in response to the battery pack temperature. A battery will still work in every other respect, except it won't respond accordingly in response to overheating. This is a fairly simple example of what could go wrong to cause a fire that would not stop the battery from working (until it failed by going on fire). The trouble with Li-ion packs is that if this happens (and it does) then the fire can very easily spread to the surrounding cells. I can see how this could cause short voltage spikes that would overcome resistance in a line to "flicker" a light.
I'd just like to add, I may be totally wrong, but I thought I'd weigh in for the fair minded rather than the conspiracy theorists on this one. Also, before anyone assumes I'm a Boeing employee, I'm not. I'm just a bloke who works with Li-ion batteries and who has seen faults similar to this in the past.