Customer SolutionsNI PXI and PACs Deliver a Portable, Real-Time Engine Life-Cycle Test Facility
Author(s):John F. Tichenor, INTAQ
Industry:Aerospace/Avionics
Product:DIAdem, LabVIEW, LabVIEW Real-Time, PXI/CompactPCI, Programmable Automation Controllers (PACs)
The Challenge:Designing a modular and portable system, called portable engine test stand (PETS), to control life-cycle testing for aircraft turbofan engines that is maintainable, scalable, and has the ability to produce data sets that transparently fit into existing data analysis systems.
The Solution:Using a National Instruments programmable automation controller (PAC) with an embedded NI PXI controller running NI LabVIEW Real-Time, engineers at Flight Test Associates (FTA) and INTAQ designed a flexible control and data acquisition system that can support 24 hour-a-day testing with three shift operations and decreased staffing.Using NI Hardware to Design a Hybrid Control and Life-Cycle Station The control system consists of two main parts: the operator control booth (OCB) and the test trailer rig (TTR). On the TTR, we installed an NI PAC for test stand control and monitoring. We outfitted the OCB with host PCs for data display, recording, and processing/analysis. We connected the two parts using fiber optics and a high-speed Ethernet. Using the high-speed connection, the OCB host systems remain a safe distance from the TTR during testing, while still maintaining a reliable communications link with the embedded PAC system. The PETS uses two separate PXI systems. The first, located on the TTR, uses LabVIEW Real-Time running on an embedded controller in an 18-slot PXI chassis. The PXI chassis includes a slew of digital PXI cards, as well as serial devices for real-time communication to the test article (TA). Using the flexibility of LabVIEW Real-Time and PXI, we have a host of options to control and safely monitor these multimillion-dollar TAs. The PAC communicates back to the OCB using a MXI4 fiber channel, installed in a second 18-slot PXI chassis. The second 18-slot PXI chassis provides the ability to collect a variety of analog signals. The system can acquire more than 1,000 data channels at rates up to 100 kS/s, as well as an additional 100 channels at rates up to 100 kS/s. We achieve reliable data acquisition from the various sensors using several NI PXI-4472 dynamic digital acquisition (DSA) modules, NI PXI M Series DAQ modules, and various SCXI signal conditioning modules. The PXI modular system architecture supports the use of common elements in other programs at INTAQ, including our state-of-the-art, in-flight acquisition systems. Using SCXI, we have a high-density, low-cost-per-channel multiplexer option for our data acquisition. With the DSA module, we can simultaneously provide health monitoring as well as sound and vibration surveying. A Flexible Automation and Control System Using LabVIEW Real-Time and PXI With the reliability of LabVIEW Real-Time, PXI modularity, and the broad range of I/O, the solution meets our requirements, increases our operational efficiencies and availability, and reduces costs. This third-generation system now meets or exceeds standards of other facilities at one-tenth of the cost. Using the control system flexibility, we have the modularity to meet operational requirements for expansion/reduction. A PETS encompasses LabVIEW on several platforms as a high- and low-level compiler. By running several platforms in the system, we achieve maximum bandwidth while maintaining integration ease. The life-cycle testing can run at full automation with minimal operator interaction. The fourth- and fifth-generation systems, currently on the drawing board, will offer more modularity at a lower cost. These upcoming systems will be easier to install and take advantage of recent NI product releases. The power of LabVIEW software and NI hardware incorporated into PETS not only provides the highest-quality, life-cycle testing, but it also provides easy modifications/upgrades to handle FAA and JAA testing. The system is ready for the toughest projects, most notably research and development programs that require regular changes, high amounts of data collection, and data analysis. NI Software for Data Analysis NI DIAdem provides the best tool available to quickly and repeatedly generate complex and intricate data analysis reports. The customer continues requests to generate DIAdem reports to save time and money. PETS now include a method to automatically provide standardized reports using DIAdem, including the ability to provide custom reports at a moments notice. Using a secure data communication network, we can incorporate data files directly into the customer database. As a result, engineers can see near real-time data from the TA. This high-level data integration provides seamless information to the engineers. The engineers can remotely monitor an engine thousands of miles away, as if the TA were located in a local facility. Additionally, LabVIEW displays provide real-time access to data for visitors, such as subcontractors, FAA and JAA representatives, and other visitors. For more information, contact: John F. Tichenor INTAQ 9000 Calle Kuehn Tucson, AZ 85715 Tel: (520) 546-3737 E-mail: johnt@intaq.com Web: www.intaq.com
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