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miniFLITS® Presentation to SCS
Presented By: Chris Oakley
September 2012
© 2012 CASSIDIAN - All rights reserved Page
2
Who we are
CASSIDIAN Electronics
EUROCOPTER ASTRIUMAIRBUS CASSIDIAN
EADS
CASSIDIAN TEST & SERVICES
© 2012 CASSIDIAN - All rights reserved Page
Cassidian Capabilities
CASSIDIAN TEST & SERVICES
Product range
Integrated Test Systems
Test Software
Test and Measurement Instruments
Maintenance Information Systems
Service range
Test Engineering Services
Test Systems Support Services
On-Site Test Operations
Obsolescence Management Services
© 2012 CASSIDIAN - All rights reserved Page
Our Pedigree
• A 50 year pedigree providing Test Systems & Services for Electronic and Optical equipment
– World leader in commercial avionics test equipment– European leader in the General Purpose ATE military market
70 airlines
50 military organisations
60+ airframes, MROs and OEMs
230+ OEM agreements
200+ airline ATEs
100+ military ATEs
300+ MRO and OEM ATEs
23+ aircraft types
13+ platforms / weapon systems
4,000+ TPS library
Customers ATEs in service Applications
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Screening Facility - Technologies
• Electronic– Analogue
– Digital
– RF
• Optical– Visible
– IR
– Laser
• Interconnect– Cable
– Backplane
• Mechanical
• Other– Pneumatic, Hydraulic, etc.
– Sensors
miniFLITS® Presentation
© 2012 CASSIDIAN - All rights reserved Page
What is miniFLITS?
A portable, ruggedised, “off the shelf” Automatic Test Set for testing Electronic Systems & Components
© 2012 CASSIDIAN - All rights reserved Page
Mk1 launched in April 2007 at Aerospace Testing Expo, Munich
Mk2 launched in September 2009
Introduced into service in 2010 by the UK Mod to help support the Lynx Helicopter
Current systems to support AFCS / CAC / HUMS / Engine Instrumentation
- Will be used for in-depot & in-field support
Significant interest from foreign military
Many major OEMs now considering capability
miniFLITS – Brief History
© 2012 CASSIDIAN - All rights reserved Page
Screening - miniFLITS®
• Full Serviceability Tester– Lynx AFCS
– Lynx CAC
– Lynx Instruments PPI tolerance validation
– Lynx Digital Torque Comparator alignment
– Cobham Fuel Valve (for AAR)
– Sea King AFCS
– Sea King HUMS validation
– Sea King Engine Instrument PPI tolerance validation
• Confidence Tester– Cobham Re-fuelling Pod
• Screening Test / Gold Standard– Technology dependant / bus based
– Application development for IP independent test
© 2012 CASSIDIAN - All rights reserved Page
How Can We Achieve Better Defence Equipment
Availability?
The reason for miniFLITS®
© 2012 CASSIDIAN - All rights reserved Page
Typical No Fault Found Scenario1st to 4th Repair Process with Screening
LOGISTICS SUPPLY PIPELINE
50K 50K 50K 50K 50K
50K NFF 50K 50K 50K
NFF
NFF
+ Reduce Repair Costs & improve agility
+ Reduction in Logistics Cost
+ Reduction Maintenance Cost
+ Reduction in Asset Levels
+ Increase in Capability & Availability
Field of Operation
Factory
NFF
© 2012 CASSIDIAN - All rights reserved Page
miniFLITS - Design Goals
General Purpose Solution – Multi-use
Multi-Platform
Efficient, Low Cost Solution
Versatile & Flexible
Easily Transportable
Ease of Maintenance
Maximum Use of COTS
Ease of Use
Highly Capable
miniFLITS’ Design Objectives
© 2012 CASSIDIAN - All rights reserved Page
miniFLITS is designed to be used by:-
OEMs of Prime Equipment
OEMs support package to customers -
improved opportunities
Service Personnel, 1st or 2nd Line Support
Platform OEMs
Field Service Teams
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Innovative testing approach with miniFLITS –“One test set for all”
1. On Aircraft Testing
2. In the Hangar
3. In the Repair Shop
4. At the Depot
5. At the Manufacturers
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Typical miniFLITS Solution
COTS Items
Interface Hardware (Jig)
Instrumentation Suite
Cabling
Self Test Hardware & Software
Test Program
Test Program Software & Licence
Application Specific (TPS)
Docking Laptop
Test Resource Chamber
Standard Rear Panel Assembly
Standard AC Power Supply
Windows Operating System & Licence
Transportation Container
© 2012 CASSIDIAN - All rights reserved Page
Measurement & Stimulus PMC Instrumentation
Large range of PMC COTS instrumentation available from multiple vendors
Some Example Instruments
Digitizer
Digital Multi-Meter
Single Channel 2G/s Digitizer
Dual Channel Digitizer
1553 and Serial Interface CAN Bus Interface
Digital Input / Output - Single slot Module
Analogue Input / Output - Single slot Module
Synchro / Resolver Measurement – 8 channels
3910 Interface Bus Module
ARINC 429 Interface Bus Module
© 2012 CASSIDIAN - All rights reserved Page
miniFLITS Software
Windows Operating System
Test Programs - National Instruments’ Labview
Industry Standard for Testing Electronics
Excellent Support Structure
Inexpensive Licensing
Test Program can be written by Cassidian T&S or User
Can be bespoke software if preferred
User Friendly Soft Panels
Excellent Fault Reporting Capabilities
© 2012 CASSIDIAN - All rights reserved Page
miniFLITS Specification
Direct CableVoltage Range : 19 VDC +/- 5%Power Consumption : 130 W
Universal Power SupplyDC/DC ConverterVoltage Range : 10 to 32 VDCPower Consumption : 150 W
AC/DC ConverterVoltage Range : 90 to 240 VACPhase : SinglePower Consumption : 150 WattsFrequency Range : 50 Hz to 400 Hz
Dimensions and MassHeight : 130mmWidth : 392mmDepth : 430mmMass : 10.8kg
Environmental CharacteristicsOperating Temperature Range : -20°C to 50°C
Storage Temperature Range : -40°C to 70°C
Humidity 5% to 95% RH, non-condensing
Altitude 15000 ft Non Operating
Transportation and StorageTransportation and Storage packaging is available for both miniFLITS and the Application Test Package.
ComplianceCE, EMC
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miniFLITS Services
Total Solution Design & Configuration
Supply miniFLITS Hardware Only
Test Program Creation & Validation
LRU Testing Service
Test Consultancy
Test Specification Production
Repair & Calibration
Obsolete ATE Replacement Analysis
miniFLITS® Applications
© 2012 CASSIDIAN - All rights reserved Page
EngineTemp
EngineSpeed
RotorSpeed
EngineTorque
Torque LRU
Aircraft Power
Measurement & Stimulus
Interface
On Wing Application – Lynx PPI Gauge Testing
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PPI Gauge System Testing – User Interface
Aircraft Selection
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PPI Gauge System Testing
Instrument Selection
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PPI Gauge System Testing
Calibration & Adjustment
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Lynx Engine Torque System
TEU
RESISTOR CODEMODULE
Pilot’s Torque Indicator
Torque Electronic Unit
Speed Signal
Torque Signal
Oil T
em
p S
ign
al
Corrected Torque
Engine Specific Code Resistor
© 2012 CASSIDIAN - All rights reserved Page
Lynx Torque System Test
TEU
RESISTOR CODEMODULE
Pilot’s Torque Indicator
Torque Electronic Unit
Speed SignalTorq
ue S
ign
al
Oil T
em
p S
ign
al
Standard Code Resistor Module
Measure TEU Response
Generated Torque Signal
© 2012 CASSIDIAN - All rights reserved Page
Replacement ATE for Testing Lynx AFCS & CAC
Obsolete System
CAC
AFCS
InterfaceJig
PL3
PL4
PL1
PL2
SK1
44412-0001-00
44413-0001-00
44405-0001-00
44406-0001-00
44407-0001-00
Bench Power Supplies
CAC
5 In Service at DSG Sealand
© 2012 CASSIDIAN - All rights reserved Page
Demonstration of Testing the Lynx Computer Acceleration Control LRU
CAC
InterfaceJig
PL3
PL444412-0001-00
44413-0001-00
Bench Power Supplies
400Hz 115v & 24v DC
CAC
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Computer Acceleration Control
Measures acceleration in vertical plane to allow:
- Automatic control of Collective Pitch
- Stabilisation of aircraft height
Measures acceleration in lateral plane to allow:
- Automatic control of cyclic pitch & rudder
- Stabilisation in Yaw
Yaw
Vertical & Lateral Acceleration
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Specification to Consider
The Test Set must be:- 1) Fully Automatic, although some limited manual interaction is
acceptable when testing certain LRU’s. 2) The Test Program must be able to test individual modules, or
a selection of modules within the amplifier. 4) The Test Set must be capable of operating from -20 degrees C
to +50 degrees C. 5) The Test Set must be man portable for ease of transportation
by one operator. 7) Commercial Off the Shelf Instrumentation must be used for
measurement and stimulus. 8) The Test Program must be written in NI Labview and Test
Stand. 9) The Test Set must operate on a Windows based operating
system.
The specification above is important as it allows the maintainerthe flexibility to move the Test System even within the hangarenvironment.
© 2012 CASSIDIAN - All rights reserved Page
miniFLITS Roadmap
Pre-Mk 1 Mk 1 Mk 2 Mk 3
Lynx AFCS / CAC
Lynx PPI Lynx EI ATP OpCom
Fuel Valve Test
SeaKing HUMS / Gauges
Optronic Screening
New platforms
More LRUs
Land Support
Enhanced screening Sensors
• LOSA Support system• Backwards compatibility• Greater capacity• Multiple formats
© 2012 CASSIDIAN - All rights reserved Page
Customer - User Feedback
“The Engine instrument test kit is working very well and once one is used to it it's possible to predict possible problems, certainly a good set. With a good aircraft set of instruments and no interruptions I've got a best time of just below 90 minutes. Not having to download and transfer files around does make it straight forward. 5* for that !”- Lynx Avionics D1 Support Eng
“The test set proved all the gauges and was an excellent aid to fault diagnosis, as designed.” - Lynx Technical Support Cell avionics desk
“The test computer was simple to use and confidence inspiring in it’s use and results” - 239 Flight SMR HMS Dauntless
miniFLITS® Demonstration