International Conference On Intelligent Control And .
International Conference on Intelligent Control and Computer Application (ICCA 2016)Design of a portable electrical and mechanicalsystem test instrument for a certain type of aircraftFeng TianChaoqun MaYongtao YuSchool of AutomationShenyang Aerospace UniversityShenyang, ChinaSchool of AutomationShenyang Aerospace UniversityShenyang, Chinamachaoqun0204@126.comSchool of AutomationShenyang Aerospace UniversityShenyang, Chinaand rapid detection[4]. In modern warfare, combat aircraft needefficient, reliable safeguard equipment to test and maintain.Because of the existing test equipment complicated operations,poor reliability, and low test efficiency, the new test equipmentdevelopment put forward higher requirements.Abstract—In view of the test and maintenance requirementsof the mechanical and electrical system of a certain type ofaircraft, a kind of portable mechanical and electrical system testinstrument for a certain type of aircraft is designed and realized.This test system enables to collect and display the states ofmechanical and electrical subsystems of a certain type of aircraft,and can output corresponding excitation to the device interface ofthe aircraft electrical system measured, collect relevant data,verify the system function and detect the fault mechanical andelectrical system. The system uses the Compact-DAQ modulardata acquisition system of US NI company as the core, the analogand discrete acquisition board as the signal acquisition, theanalog output boards and self-made discrete output module asthe excitation output signal source, with the cooperation of theself-made switching matrix, to achieve the functions of the signalacquisition and real-time display, the storage and playback ofdata and the output of excitation signal. Test results show thatthe test system has the advantages of stable performance, highreliability, high testing efficiency, simple operation, and has highversatility and portability, which can meet the needs of field test.II.SYSTEM GENERAL DESIGNA. General designElectromechanical system is a general term for the flightsupport system. It mainly includes mechanical and electricalmanagement system, fuel subsystem, power system, powersupply system, hydraulic system and environmental controlsystem and so on. Remote Interface Unit (RIU) is a part ofUMS system, which mainly completes the acquisition andoutput control of the system[2][5].Onboard RIU3Test caseRIU1Test caseNetwork cableNetwork cableRIU2Test caseNetwork cableRIU2RIU CablesRIU4Onboard CablesRIU CablesRIU4Test caseOnboard CablesThe mechanical and electrical systems on the plane are alsoknown as public equipment systems[1]. As an importantairborne systems, aircraft electrical system, includingmanagement of mechanical and electrical, hydraulic,mechanical wheel brake, environmental control, life support,fuel, the second power, electric and other subsystems, providepower, hydraulic power, equipment cooling, engine fuel,aircraft center of gravity control, emergency start engine, fire,the pilots life support and so on for the aircraft[2]. Only whenthe state parameters are in normal range, can these deviceswork normally to ensure the normal flight of the aircraft[3].Airborne electromechanical equipment is an important part ofthe aircraft, and the testing of these devices for fault detectionand resolution provided an effective basis, so the test ofairborne electromechanical equipment is very important[4].The maintenance personnel of the airborne electromechanicalequipment usually come from the mechanical profession, andhave no deep understanding to the electrical professionalknowledge. Therefore, it is necessary to design a testing systemwhich can be used to detect the failure of the airborneelectromechanical equipment in the comprehensive, accurateOnboardFig 1 Overall diagram of the systemThe test system designed in this paper mainly includes themain control computer and the test case. In order to meet thedemand of high reliability, strong anti-interference ability, highdemand for data transmission bandwidth, the system use theEthernet network as the data transmission link between maincontrol computer and test case[6]. The test case is connectedwith on-board side and RIU side through cables on-board andRIU cables. The overall diagram of the system is shown in Fig1.The main control computer realizes the control of four RIUtest case, data display and storage capabilities through thenetwork. Each test case completes corresponding signalacquisition and transmits data to the main control computerthrough the network for display and storage, and receives theThis project has been supported by Liaoning Province Natural ScienceFoundation [20141077]. This project has been also supported by LiaoningProvince Natural Science Foundation [2014024007]. 2016. The authors - Published by Atlantis PressRIU3RIU CablesRIU CablesNetwork cableI.Onboard CablesRIU1Keywords—Mechanical and electrical system; Conditionmonitoring; Functional verification; Data collection; Portable39
Test Casecontrol command of the main control computer to output setexcitation r ofpower drivesEngine and related systems14133Fuel measurement and management system20636Hydraulic system for shifting and braking14613Environmental control system / cabintemperature5914Auxiliary power system467Other systems - monitoring anddetection of electronic systems347Total632110F/VconversionVoltage OpenisolationAnalog output moduleCurrent outputAnalog output moduleVoltage outputDigitaloutput moduleFrequencyDigital outputExcitation 27V/OpensourceExcitation Ground/OpensourceDigitaloutput moduleDigital outputRS-422communication moduleRS-422Onboard CablesAdaptermoduleRIU CablesFig 2 Diagram of the test caseB. Working principle of the system.When using the test system, the adapter module, dependingon the type of test requirements and the nature of the signal,and by controlling the corresponding relay, completes theconfiguration and of the corresponding test case andconnection relationship among the test system, RIU, and Onboard side, and completes the configuration of signalacquisition channel and excitation output channel. Accordingto the signal analysis of the electromechanical system, thesignal types of the electromechanical system are mainly analogsignal, discrete signal and frequency signal. This system usesthe voltage acquisition board as the analog data acquisitionboard. The voltage signals can be directly collected by thevoltage acquisition card. The current signals need to beconverted into the corresponding voltage signal by samplingresistance, and then are acquired by the voltage acquisitioncard and then are converted to the corresponding current valuein the software. The frequency signals need to be convertedinto the corresponding voltage signal by F/V conversion andthen are acquired by the voltage acquisition card. 27V/Opensignal can be collected by discrete variables acquisition card.Ground/Open signal is converted to 27V/open signal throughthe Pull-up resistor, and then collected by discrete variablesacquisition card.TABLE I.THE NUMBER OF SPECIAL SIGNALS CONNECTED TO ANAIRBORNE ELECTROMECHANICAL AND CONTROL UNITSignalquantityDiscrete dataacquisition moduleVoltageDigital output1) The equipment and signal of the airborneelectromechanical system have the following characteristics:2) The equipments of the system are almost all mechanicalor electronic equipment.3) The equipment and signal of the airborneelectromechanical system are usually involved in energytransfer.4) The input and output characteristics vary greatly.5) Different machine electronic systems signal types varygreatly.6) The number of signals is large, the type is diverse, andthe processing is complex. Specific distribution is shown inTABLE Ⅰ[8][9].SystemSwitchNI cDAQ-9188XT CaseB. Analysis of airborne electromechanical system of signalsDifferent aircraft electronic systems perform specificfunctions to ensure the normal flight of the aircraft. With theincrease of the function, the control process is more and morecomplex, and the interface is more and more complex, andmore and more kinds of signals are involved. In the early stage,the airborne electromechanical device is controlled by a logicrelay, a fluid power device, or a separate controller, a displayand an alarm. In modern aircraft, it is required to connect thepublic equipment system to the data bus, and connect differentelectromechanical devices through the data bus, and access tothe avionics system[7].Analog dataacquisition moduleIV.DESIGN OF TEST INSTRUMENT SOFTWAREThis system realizes the data transmission between themain control computer and hardware through Ethernet. PCsoftware running on the main control computer is designed byMicrosoft software integrated development environmentproduct Studio Visual 2010.III. HARDWARE DESIGN OF THE TEST INSTRUMENTA. Design of the test caseAccording to the aircraft electrical equipment reliabilitytest conditions, this test system uses the Compact-DAQmodular data acquisition system of the NI Company as themain frame, including the adapter module, the discrete dataacquisition module, the analog data acquisition module, theRS-422 communication module, the analog output module, thedigital output module, the power supply module. The diagramof the test case is shown in Fig 2.Software testing is divided into nine modules, includinguser interface module, and help module, system self-testmodule, excitation output module, RS-422 communicationmodule, the adapter module, signal acquisition module,database management module, and task scheduling module.The software structure diagram is shown in Fig 3.40
UserUserapplication layer interface moduleTaskControl layerHardwareabstraction layerSystemself-test moduleExcitationoutput moduleHelp moduleTaskscheduling moduleRS-422communicationmoduleOn the hardware, this module detects the availability of theuniversal part of the test case, including the controllability ofthe hardware acquisition components, the availability of theacquisition components and the integrity of each channel, ofwhich the controllability and availability of the acquisitioncomponents is the main. On the software, this module,including the integrity of the data file, the integrity of the helpfile, the integrity of the data storage file and the integrity ofthe system configuration information, detects its own softwarerunning environment in order to prevent accidental deletion orloss of the key dependency. System hardware self-test flowchart is shown in Fig 6, and the system software environmentself-test flow chart is shown in Fig 7.DatabasemanagementmoduleSignalacquisition moduleAdapter moduleFig 3 System software structureA. User application layerThe user interface module is primarily responsible forproviding a set of user-friendly, operating style unifiedhuman-computer interface, convenient for the user to use thevarious functions of the software. System software serverinterface is shown in Fig 4, and System software clientinterface is shown in Fig 5.StartAcquisition cardinitializationAcquisition cardinternal self-testFault?YFault tipsNSystem self-testFault?YFault tipsNEndFig 6 System hardware self-test flowchartStartData file integrity testFault?YFault tipsNFig 4 System software server interfaceHelp file integrity testFault?YFault tipsNData storage fileintegrity testFault?YFault tipsNSystem configurationinformation integrity testFault?YFault tipsNEndFig 7 System software self-test flowchartFig 5 System software client interfaceThe task scheduling module is located between the dataacquisition and the excitation output module and the userinterface module. Its main function is to receive the taskorders through the user interface, and call the underlyingencapsulated collection and incentive resources to finish thejob tasks.Help module provides the user with convenient information,including the instructions, operating tutorial, and solutions tocommon problems on the use of the test system, guiding theuser to the correctly operate the software.B. Task control layerThe system self-test module is used to complete the selftest and alarm of the system fault, and can monitor theoperation of the software and hardware of the system in time,and ensure the normal operation of the system.The Database management module is mainly used tocomplete the storage of a variety of analog signal, discretesignal, and RS-422 data, and the working state of the specifiedperiod of time can be replayed, convenient for later analysis.41
The signals collected will be displayed and storedaccording to the RIU classification and the character of thesignals. This module will call the system analog acquisitionboard and discrete variables acquisition card to collectcontinuously all the data on the specified channel with thesupport of the channel information, and then push data to thedatabase management module, which will push data to theuser interface for display.C. Hardware abstraction layerThe Excitation output module mainly completes the settingof the excitation signal such as voltage signal, current signal,Ground/Open signal, 27V/Open signal and so on, and outputexcitation signal according to the set of quantitative. For highlevel task scheduling, the main purpose of this module is toprovide a hardware-independent excitation hardware interface,with the task related hardware information maintained in thismodule. Excitation output module flow chart is shown in Fig 8.V. EXPERIMENTAL RESULTSBefore the use of the test system, the function of eachmodule of the system must be tested strictly. Only when theentire input and output interfaces meet the designrequirements of the signal range, can the next step systemalignment test be carried out.StartFault toleranceprocessingFault？YFault tipsNCall Excitationoutput moduleFault？YA. Frequency signal testThe waveform of the signal outputted by analog excitationoutput board is 20Hz. The sinusoidal waveform displayed onthe oscilloscope is the signal waveform detected on thespecified plug pin. According to test result, the output signal isa sinusoidal waveform of 20.043Hz, and error accuracy is lessthan 0.1 Hz, fully meeting the requirements of excitationsignal. A large number of tests show that this test system cansteadily acquire signals and output excitation signals, and canachieve the expected target of the test system, which also canbe verified by the practical use. Frequency signal test result isshown in Fig 9.Fault tipsNAnalog excitation boardor discrete output moduleFault？YFault tipsNEndFig 8 Excitation output module flow chartRS-422 communication module mainly collects andanalyzes the RS-422 signal sent to the RIU from eachcontroller on the machine, and displays and stores the dataaccording to the RIU classification. The RS-422 signals aresent to the serial server through the on-board cables, and thecommunication data packets are transmitted to the maincontrol computer through the network. The main controlcomputer parses and translates the data packets into the text,and display on the interface according to the communicationprotocol.The adapter module is mainly used to control thecorresponding relay to complete the configuration of analogacquisition channel, discrete variables acquisition channel,analog output channel, and discrete variables excitation outputchannel, according to the relationship of different RIU and thecharacter of signal. In addition, it also can control thecorresponding relay to switch the relationship among the testsystem, RIU, and On-board side in accordance with the testneeds.Fig 9 Physical map of the test systemB. RS-422 serial communication testRS-422 serial communication test must be carried outunder the cooperation of the external serial port server and themain control computer serial port test software. The externalserial port server and the internal serial port are connected tothe main control computer through the switch. The externalserial port server sending interface TX and the TX- isconnected to the chassis internal serial port receiving interfaceRX and RX-. The main control computer uses serial port testsoftware to control external serial servers to send data. Beingreceived by the RS-422 serial communication module of thetesting system, the data packets are analyzed and comparedwith the data sent by the external serial port server. Ifconsistent, the RS-422 interface works properly. Multipledifferent data packet samples are used in the testing process toimprove the test coverage. Test results show that the testSignal acquisition module mainly completes theacquisition and storage of analog signal and discrete signal.Analog signal acquisition mainly completes the voltage,current signal acquisition. The voltage signals can be directlycollected by this module. The current signals need to beconverted into the corresponding voltage signal by samplingresistance, and then are acquired by this module and then areconverted to the corresponding current value in the software.Discrete variables acquisition mainly completed theacquisition of 27V/Open and Ground/Open signal. 27V/Opensignal can be directly collected by this module. Ground/Opensignal need to be converted to 27V/open signal through thePull-up resistor, and then collected by this module.42
system software function is normal, and can meet the testrequirements. RS-422 serial communication test results areshown in TABLE Ⅱ.TABLE II.VI.In this paper, this mechanical and electrical system testsystem has the following characteristics:1) Signal acquisition channel and the excitation outputchannel are designed according to the maximum capacity ofthe signal in all RIU, and have a certain margin.2) Each test case can be replaced with each other, whichcan enhance the reliability of the test system.3) Signal interface and data transmission technology ismature, in line with the development trend of future testing.Especially in data transmission, the testing system has a largebandwidth margin, which can meet the needs of the future testdata growth.4) Test systems has friendly man-machine interface, stabledata records, efficient data search, quick maintenancecharacteristics, can meet the demand of testers testing,maintenance and troubleshooting.In this paper, this mechanical and electrical system testsystem, with simulation of aircraft electronic systemequipment all input and output signals and analogelectromechanical management computer bus communicationfunction, can complete aircraft electrical system online statedetection and functional verification. A large number ofexperimental tests and practical use show that the system isstable, reliable and highly portable, which can meet therequirements of comprehensive testing, and achieve thedesired objectives.RS-422 SERIAL COMMUNICATION TEST ualified20x5AA5A55A0x5AA5A55A15.00349mAQualifiedC. Signal acquisition testSignal acquisition test can be carried out with thecooperation of signal generator and multimeter or oscilloscope.The signal generator applies the specified signal to thedesignated aerial plug pin and then the signal in the channelwill be detected by the software. In order to judge theperformance of the signal acquisition, the signal detected bysoftware will be compared with that produced by signalgenerator. According to test result, the system signalacquisition function can meet the demand. Signal acquisitiontest results are shown in TABLE Ⅲ.TABLE III.No.1234Testsignal110V420mAOpen27VSIGNAL ACQUISITION TEST Conclusion8V8 ied15 0.1mAMultimeterOpen15mAOpen27V27 1VREFERENCES[1]27.00990VQualified[2]D. Excitation output testExcitation output test can be carried out with thecooperation of the system software and multimeter oroscilloscope. The system software control excitation outputmodule to apply the specified signal to the designated aerialplug pin and then the signal in the channel will be detected bythe multimeter or oscilloscope. In order to judge theperformance of the signal acquisition, the signal that detectedby multimeter or oscilloscope will be compared with thatoutputted by excitation output module. According to test result,the system excitation output function can meet the demand.Excitation output test results are shown in TABLE Ⅳ.[3][4][5][6][7]TABLE IV.EXCITATION OUTPUT TEST onMeasuredvaluesConclusion11-10V9V9 3OpenOpenOpenQualified427V27V27.00756VQualified10 0.1mAMultimeterOpen27 1VCONCLUSIONS[9]43Moir, I. Seabridge, A.G. “Management of utility systems in theexperimental aircraft programme”. J. Aerospace, vol 9, pp. 28-34, 1986.Zheng Wei, Xie Xiangjun. “Advanced fighter integrated mechanical andelectrical system test technology research”. J. Journal of aircrafttechnology, vol 36, pp. 31-35, 2010.Jiang Zhongshan, Liu Yanping, Chen Junqing. “Research on theprotection of a certain type of aircraft based on MATLAB”. J.Aeronautical computing technology, vol 29, pp. 51-53, 2011.Fan Jun. “Research and design of the test system of airborneelectromechanical equipment” . J. Computer measurement and control,vol 27, 2013.Yang Xiaofeng, Liu Yujiao, Yao Entao. “Application of dynamic partialreconfiguration of FPGA for airborne common interface”. J.Measurement & Control Technology, vol 31, pp. 111-113, 2012.Yu Habin, Zeng Peng, Shang Zhijun. “The management mechanism fordistributed sensor network”. J. Chinese Journal of Scientific Instrument,vol 26, pp. 1203-1209, 2005.Xie Wentao. Digital Avionics (on): avionics, software and functionalparts [M]. Beijing: Aviation Industry Press, .2010, 7.ARINC 664 part 7 draft 3. Avionics full duplex switched Ethernetdetermi-nistic network[S]. Annapolist: Aeronautial Radio Incorporated,2004.Garder R. D, Andonovic I, Hunter D. K. High performance photonicavionics networking using WDM[C]. Proceedings of IEEE MILCOM1999.1999:958-962.
NI cDAQ-9188 XT Case. Analog data acquisition module Discrete data acquisition module Analog output module Digital output module Digital output module RS-422 communication module Analog output module Adapt
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