Partnership with Delta Motion Control

CCS are proud to announce our partnership with Delta Motion Control to become the official UK distributor. Through our experience in software engineering and motion control of hydraulic and electric drive systems, we have concluded that Delta Motion Control have the best range of products in this market.

We are always implementing PID control systems, but more and more companies now rely on faster and faster, micro-second response and micron positional accuracy to both speed up and improve production and measurement processes.

Following proven use of Delta Motion products in both Aerospace for high speed/force wing surface testing and Rail engineering real-time bogie motion control, we took the opportunity to become their distributor and can now assist with our engineering knowledge of their products and our associated test rigs to get the best solution for you.

RVDT Portable Test Instrument

Collins Aerospace is anew unit of Raytheon Technologies Corporation, formed by the merger of UTC Aerospace Systems and Rockwell Collins in 2018. Collins Aerospace is one of the world’s largest suppliers of aerospace and defence products and have over 300 sites globally. CCS have been involved in multiple projects with their nearby UK Enterprise and Actuation Systems sites, and now internationally, with their Singapore section via Cranfield University. 

A Rotary Variable Differential Transformer (RVDT) Test box for PAT and fault-finding purposes.

Hardware Design

  • Controller and chassis: cRIO 9040 RT Controller and FPGA backplane.
  • Display: 5 in. touch screen Win CE LCD monitor with 680*400 screen resolution.
  • Analogue Input: 4 analogue inputs 16bit, independent ADC, Voltage Range Accuracy ±10V, and simultaneous sampling.
  • Analogue Output: 4 analogue output 16bit, Voltage Range Accuracy ±10V, Output amplifier with low pass filter Signal is 3012Hz (332ms), and frequency precision can be up to 0.003%

Field programmable gate array (FPGA)

FPGAs are semiconductor devices that are based around an array of configurable logic blocks and a hierarchy of reconfigurable interconnects. The logic blocks can be configured to perform as simple logic gates or to perform complex combinational functions. The first commercially viable FPGA was invented in 1985 and since then there has been a huge increase in market competition and applications, with significant improvements in prices and performance dynamics as of 2017 broadening the range of viable applications. Some notable applications have been for hardware acceleration of the Bing search algorithm, acceleration of artificial neural networks for machine learning, and even as full systems on chips (SoC).

CCS use an add-on for NI’s LabVIEW called LabVIEW FPGA to design complex systems efficiently and effectively, this includes an integrated development environment, various IP libraries and debugging features. Here we are using the FPGA to quickly calculate the required variables without the need to upload the test data before calculating so there it is instantaneously shown on the test rig.

      Software Design

        • Initial Start-Up & Graph Screen is the first screen on start-up, once the system has booted up it will begin plotting RVDT and Encoder positions onto the graph.
        • DPMS Screen displays the positions of the RVDTs in volts, the encoder position in revolutions, and the coil Vrms (root squared mean of voltage) from secondary coil measurements. Here you can also zero the position of the encoder with the “Reset Encoder” button.
        • Settings Screen enables the operator to modify the system parameters:
          • Volts the excitation voltage supplied to the RVDT (in Vrms)
          • Oscillatory Frequency the oscillation frequency supplied to the RVDT (in Hz)
          • Pulses per Revolutions the number of pulses per revolution of the encoder

        With options to “Save”, “Revert”, and “Demo”. To save new parameters, revert to the default values, and input random numbers into the DPMs to prove they are responding correctly.

        • About Screen displaying operating system details and contact information for CCS.

        Results

        The outcome is a RVDT Test Box housed in a 19” rack inclusive of the 2 and 4 metre harnesses, breakout box and encoder. This RVDT box is not strictly a one-off piece of equipment and multiples could be sold, either to multiple companies or within a company, as an adaptable PAT and fault-finding instrument.

         

        Similar Projects

        • Aerospace Projects including other test rigs, data acquisition systems and control interfaces, for various aerospace components.
        • RVDT projects for other aerospace companies such as Comar and Goodrich.
        • More applications of FPGAs are being looked into by CCS for a variety of other projects, including other fault-detection rigs and onsite data analysis.
        • International Clients are an increasingly large part of CCS’s client base, with an multinational reputation and on-site visits key to our work.

             

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            Cryogenic Cooler Test Bench

            Honeywell Hymatic Ltd is a department of the global Fortune 100 technology company, Honeywell, and specialises in Cryogenic Cooling Solutions for Defence and Space applications.

            An adapted CCS LabStand for undertaking a wide range of tests on a cryogenic cooling system, including Stroke Capability Test, Friction Checks and Performance Baseline tests. The aim is to minimise the operator skill level required by being easy to operate and calibrate, while maintaining a very high accuracy, with clear reporting and raw data output.

            DESIGN

            Hardware

            • Mobility and Operating Interfacing:
              • The cabinet should be easy moveable between test areas, including to suit double doors and having all test connections on the right-hand side.
              • Front and rear access to the hardware.
              • Allow the operator to run the tests standing up or sitting down.
            • Operational:
              • The cabinet should be powder coated and be powered from one standard mains socket.
              • Ease of connectivity and enhanced airflow should be considered.
              • The E-Stop will stop operation while leaving the PC and control hardware active.
            • Inputs/Outputs and Connectivity:
              • BNCs for TESA mU Checker and Pressure Transducer
              • CB-A2 Socket for Keyence Triangulation
              • 9-way D-Type RS-232 for Mitutoyo Laser Mic
              • 4 mm socket for Boing Out
              • 6 mm sockets for ACT Tests 1 & 2
              • K-Type Thermocouple for Temp 1 & 2
            • Design Control and Acquisition Hardware:
              • National Instruments Hardware: cRIO Backplane, Differential Input Module, Analogue Output Module, Sinking Digital Input Module, Safe 24v Sourcing Digital Output Module, Permanent 24v Sourcing Digital Output Module.
              • Pilz Safety Controller
              • Extras: PULS low ripple power supplies, Harting 5 port switch and Brainboxes Ethernet to RS-232 converter.

              Software

              • Main Interface is the gateway to the main test bench functions and contains the user login/logout, a maintenance Task Status and navigation to the other operating screens.
              • Test Interface is designed to guide the user through each required test by displaying a series of prompts as the test progresses. It includes information on the current test, test step and instructions relevant to the test for the operator in Area A and displays a TAR mimic or a graphical representation of the test in Area B. There is also a System Trip Status Pop-Up for when there has been a critical system event. Then two reports are generated at the completion of any test run.
                • The Test Bench Summary Report containing the test unit ID info and summary of results.
                • Audit Report containing a full list of every step completed during testing.
              • Maintainer Interface allows a user to complete maintenance tasks, conduct manual testing, and view/adjust calibration.
              • Administrator Interface allows a user to add, delete or modify authorised test bench accounts.

                Results

                The test rig was delivered alongside a Software Instruction Manual and Warranty Information. Since then CCS have updated the systems software and hardware and will continue to be contactable for any future updates or issues. There has also been a more recent second Acquisition System for Honeywell in 2020 and there will be ongoing support and software updates.

                Similar Projects

                • Aerospace Projects including other test rigs, data acquisition systems (including CCS’s Daquire™) and control interfaces, for various aerospace components and companies such as Collins Aerospace, BAE Systems, and MOOG.
                • LabStand was originally developed for BAE Systems and now has been adapted for new applications, such as Clutch Testing.

                Contact

                Charlie Rodway

                Certified LabView Architect

                Principal Software Developer at CCS

                Tel: +44 (0)1926 485532

                Email: charlie@ccsln.com

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                  Flow Test Bench Update

                  BAE Systems is a British multinational defence, security, and aerospace company. To support their aircraft supplied worldwide, they provide a support package, modelled and tailored for each individual customer. Within this support package, is a second line testing solution that is used to conduct standard serviceability tests on the Line Replacement Units (LRU’s) removed from the aircraft. These component parts have mainly remained stable throughout the life of the aircraft, with only a few minor obsolescence changes have taken place.

                  The Problem. The current testing solution is now suffering from obsolescence however to the extent that BAE Systems have sought a new modern solution.

                  The Solution. The intention is to supply a bespoke fixture to serve as a dedicated test bench and act as a supply source to carry out all the necessary tests, taking the support package forward over the next 25 years.

                    Managing Updates

                    Key Issues and Proposed Solutions

                    What risk does the engine update have to previously completed LRU tests? Risk has been minimised by validation testing on over 95% of test routes on the rig since 23/01/19. There will also be a checklist of manual validation checks and normal process daily test development.

                    What LRU’s are affected by the engine update? To fit the new rudder control requirements on the existing FPGA hardware a refactoring of low-level channel control was required, which is easily validated. There is also a requirement to change the milliamp current output control for the autostablisation function of the rudder.

                    Can the pending engine update be rolled back to remove the rudder test updates without affecting LRU’s recently completed? This could possibly pose more risk than using the latest engine build we can do this by retesting the new plugin, developed for use with recent LRUs. Also fault reports have been corrected and verified in the latest build and several requested features to assist the operator in running tests have been included in the latest build.

                    What is the level of software risk or implications to all systems and LRU software? As discussed previously but also to increase confidence there is a further recommendation to re-test a small selection of older LRU’s to cover a range of functions.

                    Results

                    With the delivery of the updated system, CCS also provided them with a Post-Delivery Support Scheme for future updates and possible issues.

                     

                    Similar Projects

                    • Test Rig Upgrades for a variety of rigs including a load cell tester, hydraulic test rigs and pressure rigs.
                    • Aerospace Projects including a wide range of test rigs, data acquisition systems and control interfaces, various aerospace components.

                    Contact

                    Ian Billingsley

                    Certified LabView Architect at CCS

                    Lead Software Developer on Project

                    Tel: +44 (0)1926 485532 Ext:105

                    Email: ian@ccsln.com

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