Advanced manpower and time saving testing concept for development, production, and maintenance of electro-optical systems

In complex systems, testing each interface of a system separately is not a coherent way of testing and it reduces test quality. Especially in design verification tests, increasing test quality can be achieved by testing system level reactions and responses of all interfaces together simultaneously considering the system as a whole. In this study, a test system created for design verification tests of four different units through Hardware-in-theloop (HIL) simulation is to be explained. Design verification tests covering whole interfaces of Unit Under Test (UUT) are demonstrated with also simulations of units to be connected to UUT. The overall test system is divided into two main parts as automatic test equipment (ATE) design and HIL simulation design. The design process of ATE includes test requirements, specifications and identifications of all interfaces which belong to interconnected units in the system. The hardware selections and connections between them are accomplished for four different UUTs in such a manner that they can be tested together or separately. In the design process of HIL simulation, each sub-system connected to UUTs and UUTs themselves are considered separately. The requirements for each sub-system and each UUT are met within the interface control documents. In order to increase the quality of test, communications and the control of the electrical interfaces between each sub-system are implemented in real time. The communication interfaces consist of RS422, RS485, MILSTD-1553, Telnet and CANopen. The reactions and responses of each UUT are collected and HIL simulation is improved. Finally, the discussions about the approach of design verification tests of four different UUTs within HIL simulation and the improvement of the test quality are revealed. Further in this study, the test approach used by DEICO for HIL is discussed in detail.

This paper describes the use of neural networks in combination with algorithmic test programs to aid in improving test efficiency and accuracy, especially in test situations where bad actor test programs exist that have difficulty in detecting and isolating Unit Under Test (UUT) failures. The paper will begin with a discussion of the theoretical basis for the use of neural networks as diagnostic aids. Specifically, as an electronic device or circuit is tested, the output of the Unit Under Test (UUT) may be considered as a function of the input. Through the use of multiple tests designed to exercise system capabilities in evaluating UUT performance, the characteristic behavior of the UUT can be established. Test results obtained from the knowledge of Automatic Test System (ATS) programmed stimulus and sensor readings can be used in conjunction with neural networks in classifying good and failed UUTs based upon this characteristic behavior. Indeed, failed UUT behavior can be further classified to distinguish faulty lower-level UUT assemblies and components.

Modern avionics systems are increasingly employing the use of high speed serial data networks. High capacity Ethernet and Fibre Channel switch fabrics are commonly found at the core of theses avionics networks and it is typical to find a mix of both copper and optical media interfaces as well as multiple data link bit rates within a single aircraft system. As these switching fabrics become integral pieces of avionic suites, functional test system must be developed with the capacity to replicate the combined data streams of multiple avionics end points when the fabric is off the aircraft and becomes the Unit Under Test (UUT). This paper provides a brief technical overview of the common principals of high speed avionics Ethernet and Fibre Channel networks and switch fabrics and also addresses several key items that must be addressed when designing a test and simulation system targeted to support high speed switch UUTs.

Santa Barbara Infrared, Inc. has deployed IRWindows as an Electro-Optical test development and execution environment for military Test Program Sets (TPS). Advantages of TPS development for EO systems in the IRWindows environment are seen compared to the TPS development in ATLAS. The advantages of the IRWindows environment are: 1. Faster learning curve (graphical user interface is easier than test line interface) 2. Faster TPS development time (real time changes and asset control interface allows for faster development) 3. Asset control panel allows user to control assets real time and monitor all asset functions during development 4. Unit Under Test (UUT) image viewer allows user to set test parameters like Region of Interest more easily and more precisely 5. Continuous mode tests (like MTF allows user to real time adjustments) 6. Open architecture for test modifications This paper will outline the details of how these advantages are utilized and how not only development time is decreased but also how test execution time can be minimized making traditionally long TPS run times on EO systems more efficient.

It is the mandate of Automated Test Equipment (ATE) to minimize manual tasking and maximize automation. However, the role of the operator remains crucial to successful deployment of any ATE system. Simple tasks such as setting up the Unit Under Test (UUT), correct probing, potentiometer alignments, etc. must be taught so new operators can establish a basic level of diagnostic capability in the fleet. Current Consolidated Automated Support System (CASS) training hardware is based on F-14 and S-3 platforms which are obsolete, utilize antiquated technology, and are difficult to repair. Such hardware also limits Instructors' ability to insert and remove effective training faults. This paper describes a design concept which provides a robust training test set, including hardware, for operators to learn basic troubleshooting skills and ATE interaction. The US Navy recognized the benefits of such a system to address training deficiencies and initiated the development and acquisition of the CASS Training Set (CATS). The test set includes a variety of training scenarios which are commonly seen in the fleet, including digital tests, analog tests, Operational Flight Program (OFP) loads, alignments, Radio Frequency (RF) tests, diagnostics, etc. The CATS training UUT uses latching relays to induce consistent, repeatable hardware faults, and a microcontroller to produce software faults. Faults are applied and removed through the Test Program Set (TPS) and require no soldering or de-soldering of components. This process automates training fault insertion, extends the life of the training equipment, and provides repeatable fault signatures. Consistent training scenarios ensure lower variance in technical capabilities of course graduates. A complete hardware and software package with the look-and-feel of a fleet avionics asset, but the reliability to withstand a training environment provides a valuable tool to train ATE operators and should be a basic part of any ATE system.

The need to reduce time to market and test development costs of Printed Circuit Card Assemblies (PCAs)/Line Replaceable Modules (LRMs) Test Program Sets (TPSs), has been a major concern for both industry and government. The lack of tools is the contributing factor to lengthy development times and high initial TPS development costs and subsequent higher costs of rehosting existing TPSs. These tools are Unit Under Test (UUT) and test resource simulation software, portable test information, and virtual test development for UUT design and test engineers. The Virtual Test (VTest) Program addresses the non-availability of appropriate tools and methodologies to support the design of TPSs during initial development and subsequent life-cycle maintenance periods. VTest will provide methodologies and tools that permit the design, capture, and simulation of tester independent test requirements, UUT models, and tester resource description information. The information developed will be utilized by multiple varieties of military and commercial testers, and will provide design requirements for test adapters.

The purpose of this paper is to present a conceptual approach and to make practical recommendations on how to improve the current Automatic Test Equipment (ATE) testing and maintenance capabilities by utilizing the existing cloud computing model to build a globally linked ATE maintenance system. The basic tenet of the ATE community is to support a multi-tiered maintenance concept which, in general, is a three tiered system that is composed of organizational maintenance (O-level), intermediate maintenance (I-level), and depot maintenance (D-level) organizations. The goal of the ATE is to (1) quickly and accurately detect and isolate each fault, (2) provide software tools for analyzing historical data, and (3) gather, manage, and distribute accurate and reliable maintenance information for the failed Unit Under Test (UUT). The ATE system should provide services that will (1) maintain a repository of information that will improve fault detection and isolation, allow for off-platform assessments, document failures, and help quantify corrective actions, (2) reduce false UUT pulls, and (3) reduce repair time by prompting repair procedures. Furthermore, the ATE system should provide additional services that will help optimize the time to diagnose problems by using collected failure information and by recommending entry points into the Test Program Set (TPS) software. It should also present information to the ATE maintainer to aid in informed repair decisions which could be in the form of pilot debrief results, platform Built In Test (BIT) results, O-level test outcomes and corrective actions, and maintenance and usage history of the platform and UUT. So, based on this definition of ATE maintenance the use of cloud computing can be used to provide services to improve the overall ATE testing throughput which will result in bottom line improvements to ATE life cycle costs. By using cloud computing, which is defined to be “a model for enabling ubiquitous, convenient, on-demand network access to a shared pool of configurable computing resources (e.g., networks, servers, storage, applications, and services) that can be rapidly provisioned and released with minimal management effort or service provider interaction”, users can develop cloud computing models that will provide access to application software and databases that can be used to build a globally linked ATE maintenance system. This paper will discuss the essential characteristics of the cloud computing models and define the various flavors of cloud offerings available to designers today. This paper will also analyze the cloud computing model to arrive at a conceptual approach that can be used to enhance the current ATE Testing and Maintenance capabilities. Practical recommendations will be discussed on how to transform the current ATE Testing and Maintenance capabilities into the specific cloud computing model offerings in order to help configure a globally linked ATE maintenance system.

Consumer electronic manufacturing (CEM) companies face a constant challenge to maintain quality standards during frequent product launches. A manufacturing test verifies product functionality and identifies manufacturing defects. Failure to complete testing can even result in product recalls. In this research, a universal automated testing system has been proposed for CEM companies to streamline their test process in reduced test cost and time. A universal hardware interface is designed for connecting commercial off-the-shelf (COTS) test equipment and unit under test (UUT). A software application, based on machine learning, is developed in LabVIEW. The test site data for around 100 test sites have been collected. The application automatically selects COTS test equipment drivers and interfaces on UUT and test measurements for test sites through a universal hardware interface. Further, it collects real-time test measurement data, performs analysis, generates reports and key performance indicators (KPIs), and provides recommendations using machine learning. It also maintains a database for historical data to improve manufacturing processes. The proposed system can be deployed standalone as well as a replacement for the test department module of enterprise resource planning (ERP) systems providing direct access to test site hardware. Finally, the system is validated through an experimental setup in a CEM company.

In recent years, predictive maintenance in production has become an important tool for ensuring productivity growth and improving the quality of manufactured products. This technology uses data analytics to predict various parameters of the production process, as well as to provide manufacturers with warnings about potential problems in order to prevent premature accidents. Predictive maintenance allows manufacturers to improve production performance, reduce maintenance costs and improve equipment reliability. To effectively use predictive maintenance in an enterprise, manufacturers need effective tools for monitoring performance and preventing problems. Predictive analytics in industry helps to regulate measures related to the maintenance and restoration of equipment operability when using it for its intended purpose, and also warns of the need for unscheduled maintenance of equipment in order to prevent its failure. The paper considers the possibilities of using a predictive maintenance model of equipment that allows manufacturers to increase the reliability of production processes, suggests a method for implementing a predictive analytics system in production, and also presents a prototype of the interaction of the regulatory reference information system (NSI) and monitoring of the production line, offers a mathematical model of predictive maintenance request depending on accumulated errors.

In order to improve the actuality that a large amount of manpower, material resources and time resource are consumed because of the tediously testing procedure, the Testing System for Navigation Electron Equipment of the Unmanned Aircraft Vehicle (UAV) was researched in the paper. Through designing the system functions, testing parameter, system structure, workflow and job target, etc., the system was endued the capability to realize measurement and control fast and diagnose intelligently for the navigation electron equipment of the UAV, by the wired, portable way, which will shorten the examine and repair time during the operating and training time greatly.

Fire alarm systems are an important part of the safety concept in complex buildings. For this reason, there are high availability requirements for the systems, which must be sustained by a maintenance concept. A shortage of skilled workers and rising costs in the construction and operation of buildings are pushing these concepts ever further. This study deals with proposed changes to the maintenance strategies to achieve cost and time savings in addition to an improvement in quality. As a first part of the work, the current state of research on developments in fire alarm systems and their maintenance and inspection concepts is analyzed within a literature review. The results serve as a basis for further research, which is based on a qualitative content analysis of expert interviews and standardized surveys to identify the weaknesses in current inspection strategies and future factors influencing the methods and technology of inspections through technical innovations. As a data basis for this study, expert interviews were conducted with experts from manufacturers, industry associations, and standards bodies in order to determine the possible influencing factors. To determine their relevance for the inspection, more than 40 experts were surveyed about testing the systems. The presented results show that new technical risks, such as cyber threats and networked plant structures, are insufficiently covered by current inspection strategies. Furthermore, inspection steps can be substituted by new technologies. The most important influencing factors that can be identified here are automatic self-test functions of components and remote inspection techniques of the systems. Finally, the results are discussed within the framework of a PESTEL analysis. In conclusion, it can be stated that the integration of identified impacts in future inspection strategies brings time and efficiency benefits in the operation of systems.

Build a calculation model to measure the energy consumption of vehicle emissions, we can economically and easily achieve family type certification under multiple operating conditions and performance evaluation of specific vehicles. During the development of working conditions in Europe, the standard emission energy consumption estimation models for light vehicles and heavy vehicles were respectively developed. This paper conducts in-depth research on these calculation models, comprehensively introduces the overall process of model measurement method , explains in detail the technical details of working conditions conversion, refers to the calibration method of certification institutions, promotes the steady development of China's vehicle test and testing system, and provides technology for emission calibration. Support and guide motor vehicles to a cleaner, environmentally friendly and economical direction.

The major tasks that must be performed during development and use of an APL language test system include construction of tests and verification of test results. In addition, it is desirable that a test system be transportable to a variety of APL language implementations, be extensible, and allow easy revalidation of the language implementation. In this paper, we will describe the design, implementation, and use of an extensible, portable, self-verifying APL test system that includes facilities to generate large sets of useful tests with very little effort. The test system is based on a test definition language and on an executable formal definition of the APL language. By careful use of the test system, 150,000 self-verifying language tests were constructed in four man-weeks. Transportability was achieved by using APL as the implementation language for the test system software. The successful use and transportation of this test system demonstrates that it is relatively easy to generate tests for and in the APL language.

This study aims to produce a Computer Adaptive (CAT) system with an Items Response Theory (IRT) approach in Multimedia for Students of SMK Negeri 1 Gunung Talang. This research is a research on the development of a web-based system using the RD (Research and Development) method by applying the 4-D (Four-D) models. Basically this system is almost the same as the CBT (Computer Based Test) system, the difference from this system is that the system is able to randomize and give questions according to the ability of the test takers by using the Items Response Theory (IRT) algorithm. This system uses the Items Response Theory 3-PL model in which the parameters of this model are the level of difficulty of the items, the discriminating power of the questions and the questioning or distraction. This test system will give questions randomly to students based on the test takers' responses to the previous questions, In this system, each test taker will never get the same order of questions. Termination of the test when the test taker has reached the level of accuracy of the ability estimate, namely SE = 0.01 or if the items have been exhausted. The result of this research is a Computer Adaptive Test (CAT) system with an Items Response Theory (IRT) approach, which can be used in the process of assessing student learning outcomes. The implementation of this research is applied in the Multimedia Department of SMK Negeri 1 Gunung Talang with Printing Graphic Design Subjects.

Reproductive toxicity testing systems are used by national and international regulatory agencies. Protocols have not been standardized between agencies or even within certain agencies. Although there have been efforts at standardization, a certain amount of the differences between testing protocols is a reflection of the needs of the particular agency. New developments in in vitro techniques might lead to new test systems, but reproductive function is dependent upon the interaction of various cells and organs that cannot presently be copied in the test tube; this makes whole-animal testing systems a necessity. The present whole-animal models used by the Food and Drug Administration include the 3 segment reproduction studies used for testing drug safety and the multigeneration studies used for food additives. The Environmental Protection Agency has adopted 2 similar versions of a 2-generation study for the Office of Pesticide Programs and the Office of Toxic Substances. The National Toxicology Program, although not a regulatory agency, has taken a prominent role in reproductive toxicity testing, test system development, and test system evaluation. A new testing system, Fertility Assessment by Continuous Breeding (FACB), is currently being studied as a cost-effective and reliable alternative test system. The FACB protocol houses male and female mice as breeding pairs and removes offspring as soon as they are born during the first 14 weeks to allow continuous mating. Each breeding pair normally has up to 5 litters, and the last litter is saved to evaluate the second generation. The efficiency, reliability, and expense of the protocol are being compared to the existing testing systems.