Gulfstream 650 Jet PROTOTYPE TO PRODUCTION landing gear test station
THE CHALLENGE
The client, a leading international provider of solutions for aircraft systems and services in the business aviation markets had a need to replace their automated test bed station for the Gulfstream G650 Nose Landing Gear Retract Actuator due to its poor final test result reports. Their client, BF Goodrich, was rejecting the deliverables due to inaccurate and uncorrelatable data. We were invited to investigate the problem and to propose a viable solution along with a prototype for proof of concept. The goal was to create a new data acquisition system and the hardware interface that would allow communication with the various devices in order to automate the ATP (automated test procedure) to produce a standardized acceptance test report (for both civil and military standards) that could accompany the device under test through to its final installation stage and be accepted by the BF Goodrich aerospace factories.
This challenge was 2-fold because once we had provided a viable solution with a working prototype system, the client asked us to incorporate additional main landing gear and nose landing gear models to be tested by the test bed station. In fact, the end result was the application was developed to include the series of gulfstream jets. An additional requirement was included as so the test operator could enter additional information such as part numbers, work orders and serial numbers etc.
THE SOLUTION
We designed and developed NI (National Instruments) LabVIEW-based, real-time data acquisition system software application that could acquire precise measurements, calculate, display, save and print test results. We also designed and developed a new custom hardware interface, where all the pre-existing test station devices would connect and allow for communication with the test computer.
We removed all pre-existing control and acquisition devices and installed a new NI 16Bit DAQ (data acquisition unit) along with a Novotechnik LWX linear position transducer which we then connected to a MUK signal conditioner. This design provided the required accurate measurements needed to satisfy the requirements of the ATP (automated test procedure) and provide the measurements used to plot correlatable data.
The automated test application could now record measurements from the NI 16Bit DAQ and the linear position transducer as the landing gear actuator was being exercised (extended and retracted) in the test bed. Using these acquired measurements, we were now able to automatically measure and document the piston stroke as well as use several mathematical formulas to calculate the required extend and retract times and snubbing times and positions.
The test operator is now guided through the various test step procedures with an easy-to-use UI. Where through the use of on-screen images, instructions and messages, the automated testing process assures the user had made the required connections and then begins to correctly test and produce a standardized acceptance test report (for both industry and military standards) that will accompany the device under test through to its final installation stage.
During this procedure, the test operator is prompted to enter additional UUT (unit under test) information such as ATP revision, part number, work order and serial numbers. Once all the elements had been tested and the process was complete, the measured data and a pass-fail result were visually displayed on the screen. The test operator then had the option save and print a copy of the test report which would accompany the device under test through the various production stages.
The client additionally requested the ability to add additional units to be tested in the same test bed. The automated software application now allows for the test operator to be able to select and test one (1) of nine (9) different actuators in the same test bed. The automated software applicated needed to support acceptance testing for the:
- Main landing gear for the Gulfstream G650
- Nose landing gear for the Gulfstream G650
- Main landing gear for the Gulfstream G600
- Nose landing gear for the Gulfstream G600
- Main landing gear for the Gulfstream G500
- Nose landing gear for the Gulfstream G500
- Main landing gear for Top Secret Military Jets
- Nose landing gear for Top Secret Military Jets
- Main landing gear for helicopters with retractable landing gear
Finally, we provided the client with the full NI LabVIEW source code for the automated test application, an automated test application installer (executable), the technical schematics and the bill of materials for the hardware interface so their in-house engineers could modify, repair or duplicate the test station.
Additionally, the automated test application we designed and developed runs on the free NI LabVIEW runtime engine, so no additional NI LabVIEW licenses are required for any additional duplicate stations.
This new test station allows our client to test various main landing gear models automatically, whether for production acceptance or rebuilds and repairs. In one footprint in a corner of the production area, this test station can keep up with the growing production quantity. Furthermore, this test station was developed as so additional devices for test could be easily added to the test station software with minimal software development and effort.
Our clients have reduced their software development and maintenance costs by developing this real-time control and data acquisition system software application to automate the main landing gear test bed station with a single software environment, NI LabVIEW.
Gulfstream 650 Jet PROTOTYPE TO PRODUCTION landing gear test station
THE CHALLENGE
The client, a leading international provider of solutions for aircraft systems and services in the business aviation markets had a need to replace their automated test bed station for the Gulfstream G650 Nose Landing Gear Retract Actuator due to its poor final test result reports. Their client, BF Goodrich, was rejecting the deliverables due to inaccurate and uncorrelatable data. We were invited to investigate the problem and to propose a viable solution along with a prototype for proof of concept. The goal was to create a new data acquisition system and the hardware interface that would allow communication with the various devices in order to automate the ATP (automated test procedure) to produce a standardized acceptance test report (for both civil and military standards) that could accompany the device under test through to its final installation stage and be accepted by the BF Goodrich aerospace factories.
This challenge was 2-fold because once we had provided a viable solution with a working prototype system, the client asked us to incorporate additional main landing gear and nose landing gear models to be tested by the test bed station. In fact, the end result was the application was developed to include the series of gulfstream jets. An additional requirement was included as so the test operator could enter additional information such as part numbers, work orders and serial numbers etc.
THE SOLUTION
We designed and developed NI (National Instruments) LabVIEW-based, real-time data acquisition system software application that could acquire precise measurements, calculate, display, save and print test results. We also designed and developed a new custom hardware interface, where all the pre-existing test station devices would connect and allow for communication with the test computer.
We removed all pre-existing control and acquisition devices and installed a new NI 16Bit DAQ (data acquisition unit) along with a Novotechnik LWX linear position transducer which we then connected to a MUK signal conditioner. This design provided the required accurate measurements needed to satisfy the requirements of the ATP (automated test procedure) and provide the measurements used to plot correlatable data.
The automated test application could now record measurements from the NI 16Bit DAQ and the linear position transducer as the landing gear actuator was being exercised (extended and retracted) in the test bed. Using these acquired measurements, we were now able to automatically measure and document the piston stroke as well as use several mathematical formulas to calculate the required extend and retract times and snubbing times and positions.
The test operator is now guided through the various test step procedures with an easy-to-use UI. Where through the use of on-screen images, instructions and messages, the automated testing process assures the user had made the required connections and then begins to correctly test and produce a standardized acceptance test report (for both industry and military standards) that will accompany the device under test through to its final installation stage.
During this procedure, the test operator is prompted to enter additional UUT (unit under test) information such as ATP revision, part number, work order and serial numbers. Once all the elements had been tested and the process was complete, the measured data and a pass-fail result were visually displayed on the screen. The test operator then had the option save and print a copy of the test report which would accompany the device under test through the various production stages.
The client additionally requested the ability to add additional units to be tested in the same test bed. The automated software application now allows for the test operator to be able to select and test one (1) of nine (9) different actuators in the same test bed. The automated software applicated needed to support acceptance testing for the:
- Main landing gear for the Gulfstream G650
- Nose landing gear for the Gulfstream G650
- Main landing gear for the Gulfstream G600
- Nose landing gear for the Gulfstream G600
- Main landing gear for the Gulfstream G500
- Nose landing gear for the Gulfstream G500
- Main landing gear for Top Secret Military Jets
- Nose landing gear for Top Secret Military Jets
- Main landing gear for helicopters with retractable landing gear
Finally, we provided the client with the full NI LabVIEW source code for the automated test application, an automated test application installer (executable), the technical schematics and the bill of materials for the hardware interface so their in-house engineers could modify, repair or duplicate the test station.
Additionally, the automated test application we designed and developed runs on the free NI LabVIEW runtime engine, so no additional NI LabVIEW licenses are required for any additional duplicate stations.
This new test station allows our client to test various main landing gear models automatically, whether for production acceptance or rebuilds and repairs. In one footprint in a corner of the production area, this test station can keep up with the growing production quantity. Furthermore, this test station was developed as so additional devices for test could be easily added to the test station software with minimal software development and effort.
Our clients have reduced their software development and maintenance costs by developing this real-time control and data acquisition system software application to automate the main landing gear test bed station with a single software environment, NI LabVIEW.
