Konrad Aerospace HASS Testsystem

For quality assurance reasons under practical conditions, the so called Stress Screening Tests were developed for the aerospace industry. By so doing , DUTs are exposed to temperature cycles between -40°C to +85°C while shaking the DUTs along several axes. Early failures and manufacturing defects will be detected with high certainty.

The KT- High Accelerated Stress Screening Test System was developed as a standard solution for the aerospace industry and equipped with PXI instruments. These include a 7.5-digit multi meter, various digital I / O boards and multiplexers, CAN interfaces and extensive options for powering DUTs (AC and DC sources for all aviation relevant voltages).

We equiped  this test system with the universal KT-Climatic-Chamber-Server. This allows running climatic profiles with correlated test sequences.  Different climatic chambers from various manufacturers can be interfaced using plug-ins.

The comprehensive software package includes tools for efficient development and production ramp up.

Within a short amount of time test engineers can use the KT Sequence Generator software to automatically generate test sequences, based on requirement documents and test step templates.

With KT-DEMA a library of interactive instrument panels are available, which can directly be integrated in the test program. The execution of test programs in production is done using the KT operator interfaces.

 

Benefits

  • Universal Test System - Supports a wide range of technologies which makes it easily customizable to meet specific customer requirements
  • Reduce test time and Time- to - Market thus reducing Cost of Production
  • Scalable and Modular implemented test platforms guarantee easy maintenance and throughput balancing
  • Flexible - Can be applied to many programming configurations
  • Very Reliable - Features ensure efficient  data integrity, uninterrupted process and production flow
  • Improved Failure Simulation Configurations
  • A special feature of this test system is verification by means of a database for all test procedures. This includes the cross check of the test adapters with each DUT, all relevant test sequences, and parameters

Customer requirements

  • DUT interfacing via exchangeable test adapters
  • Aerospace voltage 115V/400Hz
  • Flexible supply and switching of multiple DC and AC voltages to the DUTs
  • Stimulation and measurement of selected signals for failure detection by using commercial off the shelf (COTS) instrument based test system
  • Control of climatic chamber and shaker (HASS chamber) as a subject to test sequences
  • Automated verification of all software and hardware parameters
  • All test result data are stored in result files, compliant to aerospace standards, e.g. ABD0100. Furthermore, software tools such as KT-STAT are used for SPC analysis to simplify a continuous improvement of production quality.

Software

  • NI TestStand: Sequential Control, Editor, Debugger
  • NI LabVIEW: Test Step libraries
  • KT Operator Interface: User Interface, Debugging
  • KT Project: Test Step library, Functional Test
  • KT Sequence Generator: Automated generation of test sequences based on requirement documents
  • KT DEMA: Soft-Front Panels for interactive operation of instruments
  • KT Climatic Chamber software
  • KT Environmental-Server-Application
  • The KT HASS Test System is a universal test solution for cost efficient test of typical LRUs, using commercial instruments. Specific aerospace requirements, such as the Airbus ABD0100 are supported.

Hardware

  • PXI-Based Test System with ABex® Extension
  • Industrial PC as a system controller with an MXI interface
  • NI PXI-1045 18 Slot Chassis
  • MXI-Express Interface
  • PXI-4071 7½ Digit DMM
  • PXI-6528 48 Channel Digital I/O
  • PXI-2527 32 Channel Multiplexer
  • ME9000 8 Port Serial Interface
  • NI PXI-8464/2-Port CAN Interface
  • AC and DC Power Multiplexer within separate 19” racks, controlled via NI-6501 USB-Digital I/O ModuleUPSKT Power Supply UnitAs the interface between DUTs and test system, a solution from Virginia Panel has been chosen. It includes exchangeable adapters with reliable connections to over 20,000 mating cycles without exchanging contacting pins.

 

Power Supply

  • California Instruments AC Source Lx Series, 115V, 400 Hz, 4500 VA, three-phase 
  • Agilent N5746A, 0…40V, 19A, 760W
  • Agilent N6700 Two-Channel 35V, 3A, 100W each