Data processing: measuring – calibrating – or testing – Testing system – Of circuit
Reexamination Certificate
1999-01-29
2001-07-31
Shah, Kamini (Department: 2857)
Data processing: measuring, calibrating, or testing
Testing system
Of circuit
C702S121000, C702S123000, C714S741000, C714S742000
Reexamination Certificate
active
06269319
ABSTRACT:
FIELD OF THE INVENTION
This invention pertains to test systems, in general, and to an integration test system for aircraft, in particular.
BACKGROUND OF THE INVENTION
An aircraft is an assembly of numerous interacting mechanical and electrical components that need to function properly for the aircraft to operate safely. An important step in the manufacture of aircraft is the testing of each component in order to verify the design of the component. The operability of a newly designed component when integrated into the environment of an aircraft is essential to a determination of the viability of the design. Testing of this kind is referred to as “integration” testing. Almost all aircraft components are subjected to integration testing prior to installation in the aircraft. To perform such testing, it is important that the component is tested in an environment that simulates the conditions that will occur during flight. This testing requires that the component receives stimuli which are representative of the stimuli that would be received during actual flight conditions and that the component responds to the stimuli in a predictable and correct fashion.
One method of testing newly designed components is to rely either on flight testing of the aircraft or on system testing when the aircraft is on the ground. Flight testing, as the name implies, involves flying the aircraft in order to ensure that the various components operate properly with each other and that the design of a new component or the new design of an existing component operates as expected. Flight testing, while useful, has limitations. In flight testing it is difficult, if not impossible, to expose an aircraft to all conditions to which it might be exposed in order to observe how the component will respond. For example, environmental conditions such as sudden cross winds cannot be developed on command. Also, complex aircraft, such as modem commercial airliners, comprise a large number of components that are assembled into numerous systems. The complexity increases even more with modem military aircraft. The components and systems must be subjected to numerous test procedures in order to ensure that the design functions properly. It is neither an efficient use of time nor an efficient use of resources to repeatedly flight test an aircraft solely to ascertain whether a specific assembly of components are performing as anticipated. In addition, a number of test procedures involve verifying or determining the operation of the aircraft under potentially threatening or extreme conditions such as high wind, low altitude flight conditions. Testing an aircraft under such conditions can jeopardize the safety of both the aircraft and the flight crew.
The alternative to flight testing an aircraft is ground testing utilizing integration test stations. Integration test stations are distinct and separate from test stations that are utilized for testing during manufacture or subsequent to manufacture for maintenance. One key distinction is that integration test stations are used to verify design and operation of the component being tested in a simulated operational environment, whereas other test equipment is used for verification of operability on equipment or components after validation.
All prior integration testing systems are aircraft specific. In many instances the testing systems are even aircraft version specific. It is highly desirable that an integration test system be available to be operable with multiple aircraft and to be easily changeable from one aircraft to another.
SUMMARY OF THE INVENTION
In accordance with the principles of the invention an integration test station is provided that may be utilized for multiple aircraft and/or aircraft versions. An integration test station in accordance with the invention has the capability to perform acceptance testing and permits the user to “break into the system” to troubleshoot design anomalies as well as perform design performance tests. The integration test system supports an integration capability into which other real systems can be easily connected or simulated in an endless variety of possible combinations. This capability allows system developers to verify design operation and interaction between subsystem elements.
In a system in accordance with the invention, simulation and monitoring functions are modularized. Circuit cards and cables are reused from configuration to configuration. Control and monitoring aspects of simulation and monitoring functions are supported with a power and communications core. Signal paths from simulation cards are routed through jumper connectors/plugs that permit connectivity to real aircraft components.
Software is provided in a host computer that contains a core operating system that in turn calls down different simulation or monitor configurations to match the specific system under test. Configurations are user selectable during system power up.
Simulation and monitor modules are connectorized with connectors utilized to map to specific system wiring. The connectors can be easily changed to switch between different systems.
In accordance with the principles of the invention, an integration test station includes software that is reconfigured for each new configuration for which testing is to be performed. Further in accordance with the principles of the invention, an integration test station includes a cable arrangement that permits connection to a large number of different aircraft components and permits validation of component designs. The cable arrangement is connectorized to a “personality module” that maps wiring by different functions to various circuit boards.
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Neisch Jonathan C.
Turner Donald E.
Bui Bryan
Cave LLP Bryan
Shah Kamini
The McDonnell Douglas Corporation
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