Automated test apparatus for aircraft flight controls

• US 5,023,791 A
• Filed: 02/12/1990
• Issued: 06/11/1991
• Est. Priority Date: 02/12/1990
• Status: Expired due to Term

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Reynolds, Robert C., Herzberg, Garry G.
• Primary Examiner(s): Chin, Gary
• Application Number:
  US07/478,358
• Time in Patent Office: 484 Days
• Field of Search: 364/424.01, 364/424.03, 364/424.04, 364/431.01, 364/578, 364/550, 364/551.01, 364/579, 364/580, 324/73.1, 371/15.1, 371/25.1, 371/26, 371/27, 371/71, 73/117.2
• US Class Current: 701/35
• CPC Class Codes: G01R 31/008 on air- or spacecraft, railway rolling stock or sea-going vessels
• CPC Class Codes: G05B 23/0256 injecting test signals and analyzing monitored process response, e.g. injecting the test signal while interrupting the normal operation of the monitored system; superimposing the test signal onto a control signal during normal operation of the monitored system
• CPC Class Codes: G05B 23/0283 Predictive maintenance, e.g. involving the monitoring of a system and, based on the monitoring results, taking decisions on the maintenance schedule of the monitored system; Estimating remaining useful life [RUL] preventive maintenance, i.e. planning maintenance according to the available resources without monitoring the system G06Q10/06

Abstract

An automated test apparatus (10) for testing the flight controls system of an aircraft (12) as part of an integrated system for testing a plurality of aircraft systems. The automated test apparatus includes a system controller (16) having memory (18) for storing programmed instructions that control operation of the automated test apparatus, and for storing resulting flight controls system test data. The automated test apparatus includes a keyboard (20), a touch screen (24), and a tape drive (22) for entering programmed instructions and other information into the automated test apparatus, and for outputting test data from the system controller. Instruments (26) included in the automated test apparatus and controlled by the system controller generate test signals that are input to the aircraft'"'"'s flight controls system, and monitor resulting test data signals that are produced by the flight controls system. The automated test apparatus is connected by an interface cable (28) to an onboard central maintenance computer (30) included in the aircraft. The central maintenance computer includes a non-volatile memory that is programmed to run onboard tests of the flight controls system, and is controlled by the system controller during testing in accordance with the programmed instructions to run the onboard tests.

Claims

1. In an integrated system for testing a plurality of systems on an aircraft, an automated test apparatus for testing a flight controls system of the aircraft, said apparatus comprising:

a system controller having memory means for storing programmed instructions that control operation of the automated test apparatus to automatically test the flight controls system and for storing resulting flight controls system test data;

information entry means for entering information into said system controller;

output means for outputting said test data from said system controller;

instrumentation means for generating a first set of signals that are input to the flight controls system, and for monitoring a second set of signals that are produced by the flight controls system, said instrumentation means being controlled by said system controller and connected to provide digital signals to said system controller corresponding to the second set of signals; and

interface means, connecting said system controller to the flight controls system, for automatically controlling and monitoring the flight controls system in accordance with the programmed instructions so that a plurality of functions of the flight controls system are effected while the aircraft is on the ground, to test the operation of the flight controls system in coordination with the first set of signals generated by said instrumentation means.

2. The automated test apparatus of claim 1, wherein the aircraft includes an onboard maintenance computer that is connected to the flight controls system of the aircraft and a non-volatile memory that is programmed to run onboard tests of the flight controls system, said onboard maintenance computer being connected through said interface means to said system controller and controlled thereby in accordance with the programmed instructions to run the onboard tests of the flight controls system, results of the onboard tests being conveyed through said interface means to said system controller.

3. The automated test apparatus of claim 2, wherein the flight controls system of the aircraft includes line replaceable units for controlling and monitoring aircraft flight controls, and wherein said system controller controls the line replaceable units in accordance with the programmed instructions, to simulate in-flight conditions of the aircraft during testing of the aircraft on the ground.

4. The automated test apparatus of claim 3, wherein the aircraft'"'"'s line replaceable units include a flap control unit and said system controller controls said flap control unit to simulate the in-flight positioning of the aircraft'"'"'s flaps during said ground testing.

5. The automated test apparatus of claim 3, wherein the aircraft'"'"'s line replaceable units include a proximity switch electronics unit and said system controller controls said proximity switch electronics unit to simulate the in-flight configuration of the aircraft'"'"'s proximity switches during said ground testing.

6. The automated test apparatus of claim 3, wherein the aircraft'"'"'s line replaceable units include an air data computer and said system controller controls said air data computer to simulate in-flight altitude and air speed of the aircraft during said ground testing.

7. The automated test apparatus of claim 1, wherein the flight controls system of the aircraft includes line replaceable units for controlling and monitoring aircraft flight controls, said system controller being connectable to the aircraft through said interface means to replace particular line replaceable units that have been removed from the aircraft and to emulate the function of the removed line replaceable units in accordance with the programmed instructions during said testing of the flight controls system.

8. The automated test apparatus of claim 1, wherein the flight controls system of the aircraft includes pressure sensing devices and said instrumentation means comprise means for pneumatically stimulating the pressure sensing devices to simulate in-flight air speeds and altitudes in the flight controls system while the aircraft is on the ground.

9. The automated test apparatus of claim 1, wherein the instrumentation means include transducers, placeable at selected points on the aircraft, to augment the testing of the flight controls system by measuring specific parameters associted with operation of the flight controls at the selected points on the aircraft.

10. The automated test apparatus of claim 1, further comprising remote means for manually entering information in response to instructions output on the remote means, the remote means being connected to said system controller and disposed in the flight deck of the aircraft during said tests of the flight controls system, the system controller causing test instructions to be output on the remote means in accordance with the programmed instructions, thereby directing a test operator to set controls of the flight controls system.

11. The automated test apparatus of claim 1, wherein said system controller, information entry means, output means, and instrumentation means are mounted on a cart that is external to the aircraft and is mobile, enabling the cart to be moved to the aircraft to test the flight controls system.

12. The automated test apparatus of claim 1, wherein the system controller is operative to transmit the test data to a central storage facility for integration with other test data produced by the integrated system.

13. An automated test apparatus for testing a flight controls system of an aircraft, the aircraft including an onboard maintenance computer that is connected to the flight controls system and a non-volatile memory that is programmed to run onboard tests of the flight controls system, said apparatus comprising:

a system controller having memory means for storing programmed instructions that control operation of the automated test apparatus to automatically test the flight controls system and for storing flight controls system test data;

information entry means for entering information into said system controller;

output means for outputting said test data from said system controller;

instrumentation means for generating a first set of signals that are input to the flight controls system, and for monitoring a second set of signals that are produced by the flight controls system, said instrumentation means being controlled by said system controller and connected to provide digital signals to said system controller corresponding to at least some of the second set of signals; and

interface means connecting said system controller to at least said onboard maintenance computer, said system controller controlling the onboard maintenance computer in accordance with the programmed instructions to run the onboard tests of the flight controls system while the aircraft is on the ground, in coordination with the first set of signals generated by said instrumentation means, results of the onboard tests being conveyed through said interface means to said system controller.

14. The automated test apparatus of claim 13, wherein the flight controls system of the aircraft includes line replaceable units for controlling and monitoring aircraft flight controls and wherein said system controller controls the line replaceable units in accordance with the programmed instructions, to simulate in-flight conditions of the aircraft during testing of the aircraft on the ground.

15. The automated test apparatus of claim 14, wherein the aircraft'"'"'s line replaceable units include a flap control unit and said system controller controls said flap control unit to simulate the in-flight positioning of the aircraft'"'"'s flaps during the ground testing.

16. The automated test apparatus of claim 14, wherein the aircraft'"'"'s line replaceable units include a proximity switch electronics unit and said system controller controls said proximity switch electronics unit to simulate the in-flight configuration of the aircraft'"'"'s proximity switches during said ground testing.

17. The automated test apparatus of claim 14, wherein the aircraft'"'"'s line replaceable units include an air data computer and said system controller controls said air data computer to simulate in-flight altitude and air speed of the aircraft during said ground testing.

18. The automated test apparatus of claim 13, wherein the flight controls system of the aircraft includes line replaceable units for controlling and monitoring aircraft flight controls, said system controller being connectable to the aircraft through said interface means to replace particular line replaceable units that have been removed from the aircraft and to emulate the function of the removed line replaceable units in accordance with the programmed instructions during said testing of the flight controls system.

19. The automated test apparatus of claim 13, wherein the flight controls system of the aircraft includes pressure sensing devices and said instrumentation means comprise means for pneumatically stimulating the pressure sensing devices to simulate in-flight air speeds and altitudes in the flight controls system.

20. The automated test apparatus of claim 13, wherein the instrumentation means include remote transducers, placeable at selected points on the aircraft, to augment the testing of the flight controls system by measuring specific parameters associated with operation of the flight controls at the selected points on the aircraft.

21. The automated test apparatus of claim 13, further comprising remote means for manually entering information in response to instructions output on the remote means, the remote means being connected to said system controller and disposed in the flight deck of the aircraft during said tests of the flight controls system, the system controller causing test instructions to be output from the remote means in accordance with the programmed instructions, thereby directing a test operator to set controls of the flight controls system.

22. The automated test apparatus of claim 13, wherein said system controller, information entry means, output means, and instrumentation means are mounted on a cart that is external to the aircraft and is mobile, enabling the cart to be moved to the aircraft to test the flight controls system.

23. A method for automatically testing a flight controls system of an aircraft on the ground, the aircraft including an onboard maintenance computer that is connected to the flight controls system and a non-volatile memory that is programmed to run onboard tests of the flight controls system, said method comprising:

storing programmed instructions for testing the flight controls system in a system controller having memory capacity;

interfacing the system controller with the aircraft'"'"'s onboard maintenance computer during the tests, to control the onboard maintenance computer in accordance with the stored programmed instructions;

generating a first set of signals with instrumentation means controlled by the system controller in accordance with the programmed instructions to run the onboard tests of the flight controls system;

monitoring a second set of signals produced by testing of the flight controls system;

storing test data corresponding to the second set of signals in the system controller; and

outputting the stored test data to an output device.

24. The method of claim 23, further comprising the step of simulating of in-flight conditions of the aircraft during testing of the aircraft while on the ground.

25. The method of claim 23, further comprising:

removing line replaceable units included in the aircraft; and

emulating the function of the removed line replaceable units with the system controller in accordance with the stored programmed instructions during said testing of the flight controls system.