Open systems architecture solutions for military avionics testing

Raytheon makes extensive use of open systems architecture methods in developing special test equipment (STE) for testing military avionics equipment. Such use has resulted in significant cost and schedule savings in the development of production test equipment for radar and infrared systems. With open systems architectures, a test system can be assembled using COTS products. This brings economies of scale to test equipment, which is normally built in very low quantities. Therefore, the potential cost savings due to COTS usage is proportionately greater in STE than in the higher volume avionics systems that are tested. A second major benefit of using COTS products is that test system development schedule cycle time is greatly reduced. This paper describes the application of Open Systems Architectures (OSA) to avionics testing. The following major architectures are surveyed: VME bus, VXI bus, IEEE GPIB, IEEE 1149.1 JTAG test bus, 1553 Military Bus, Fibre Channel, and COTS Test Applications Software. We describe how the benefits of OSA have been extended at Raytheon into achieving vertical test commonalities. The flexibility of OSA can be exploited to provide an overall optimum test solution, taking all levels of test into account. For example, test systems can be tailored with COTS products to provide integrated methods for avionics tests at the module, unit, and system levels. Test systems can be configured to maximize the reuse of COTS hardware over all test levels. Test software can also be programmed to optimize such reuse over levels of test. Additional test verticality synergies derived from such OSA usage are described, including: test false alarm avoidance; test cones of tolerance optimization; and efficient test of field returns     

Sustainment of legacy automatic test systems: lessons learned on TPS transportability

Sustainment of legacy automatic test systems (ATS) saves cost through the re-use of software and hardware. The ATS consists of the automatic test equipment (ATE), the test program sets (TPSs), and associated software. The associated software includes the architecture the TPSs run on, known as the control software or test station test executive. In some cases, to sustain the legacy ATS, it is more practical to develop a replacement ATE with the latest instrumentation, often in the form of commercial off-the-shelf (COTS) hardware and software. The existing TPSs, including their hardware and test programs, then need to be transported, or translated, to the new test station. In order to understand how to sustain a legacy ATS by translating TPSs, one must realize the full architecture of the legacy ATS to be replaced. It must be understood that TPS transportability does not only include translating the original TPS from an existing language (such as ATLAS) to a new language (such as "C") to run on a new test station, but includes transporting the run-time environment created by the legacy ATS. This paper examines the similarities and differences of legacy ATE and modern COTS ATE architectures, how the ATS testing philosophy impacts the ease of TPS transportability from legacy ATE to modern-day platforms, and what SEI has done to address the issues that arise out of TPS transportability.     

Applying independent verification and validation to the automatictest equipment life cycle

Automatic Test Equipment (ATE) is becoming increasingly more sophisticated and complex, with an even greater dependency on software. With the onset of Versa Modular Eurocard (VME) Extensions for Instrumentation (VXI) technology into ATE, which is supposed to bring about the promise of interchangeable instrument components. ATE customers are forced to contend with system integration and software issues. One way the ATE customer can combat these problems is to have a separate Independent Verification and Validation (IV&V) organization employ rigorous methodologies to evaluate the correctness and quality of the ATE product throughout its life cycle. IV&V is a systems engineering process where verification determines if the ATE meets its specifications, and validation determines if the ATE performs to the customer's expectations. IV&V has the highest potential payoff of assuring a safe and reliable system if it is initiated at the beginning of the acquisition life cycle and continued throughout the acceptance of the system. It is illustrated that IV&V effects are more pronounced when IV&V activities begin early in the software development life cycle, but later application of IV&V is still deemed to have a significant impact. IV&V is an effective technique to reducing costs, schedule, and performance risks on the development of complex ATE, and a “tool” to efficiently and effectively manage ATE development risks. The IV&V organization has the ability to perform a focused and systematic technical evaluation of hardware and software processes and products. When performed in parallel with the ATE development life cycle, IV&V provides for early detection     

The problem with aviation COTS

Commercial Off the Shelf (COTS) has become a byword for acquisition reform, but there are significant risks associated with the use of COTS products in military systems. These risks are especially acute for aviation systems. This paper explains how COTS can negatively affect military acquisitions and gives ideas on how to plan and resolve COTS caused problems     

C-17 successful application of existing automatic test equipment

The C-17 Program utilizes existing B-1B Automatic Test Equipment (ATE). The C-17 decision is in harmony with the Air Force emphasis on reducing proliferation of unique ATE. The ATE selection was made after consideration of cost, performance and supportability tradeoffs. Minimal augmentation of the government inventoried equipment was required which did not affect the existing hardware and software configuration, This approach significantly reduced C-17 program ATE development costs and afforded the program the use of established logistics elements and support structure. The C-17 program demanded concurrency of support structure and aircraft development-the ATE solution met that demand by reducing risks to a manageable level for both test program set development, and Air Force operation and training requirements     

Continuing challenges in lithium battery development

In these days of emphasizing standardization, Acquisition Reform, Non-Developed Items (NDI) and Commercial-Off-The-Shelf (COTS) technologies, we are facing new challenges associated with these trends. Program managers are pressured to use a standard or COTS battery, while simultaneously, the new systems being developed have increasingly complex and demanding power requirements. Hardware must be developed with shorter schedules, and policies of Acquisition Reform limit the amount of control the government has over the development of a given item. In this paper, we review battery development efforts that have resulted in unexpected problems. Relevant data from both current and past test programs are presented. Recommendations are provided concerning how to best avoid duplication of effort, while ensuring that the final product will have the best chances of succeeding     

A cost effective critical space systems design approach

NASA-ISC requires avionics platforms capable of serving a wide range of applications in a cost-effective manner. In part, making the avionics platform cost effective means adhering to open standards and supporting the integration of COTS products with custom products. Inherently, operation in space requires low power, mass, and volume while retaining high performance, reconfigurability, scalability, and upgradability. The Universal Mini-Controller (UMC) project is based on a modified PC/104-Plus architecture while maintaining full compatibility with standard COTS PC/104 products. The architecture consists of a library of stackable building block modules, which can be mixed and matched to meet a specific application. A set of NASA developed core building blocks, (e.g. processor card, analog input/output card, high level analog card, and a Mil-Std-1553 card) were constructed to meet critical functions and unique interfaces     

CASS: design for supportability

An Automatic Test Equipment (ATE) system that is supportable provides all of the operational requirements necessary to support fleet weapon systems, from installation, to operation and maintenance, to disposal. To be supportable, ATE must then minimize facility, personnel, training, supply support and support equipment impacts. Furthermore, should the ATE fail to operate, impacts to the systems which it supports must also be minimized     

Software architecture requirements for DoD automatic test systems

The DoD has achieved success with recent automatic test equipment (ATE) families, as evidenced by the navy's consolidated automated support system (CASS) and the army's integrated family of test equipment (IFTE) programs. However, as these systems age, the increased requirements for technology insertion due to instrument obsolescence and the demands of advanced electronics are becoming evident. Recent advances in test technology promise to yield reduced total ownership costs (TOC) for ATE which can incorporate the new technology. The DoD automatic test system (ATS) executive agent office (EAO) objective is to significantly reduce total ownership cost. Several objectives have been identified including use of synthetic instruments, support for legacy test product sets (TPSs), and more efficient ways of developing TPSs. The NxTest software architecture will meet the objectives by providing an open systems approach to the system software. This will allow for the incorporation of commercial applications in the TPS development and execution environments and support current advances in test technology     

Successful deployment of commercial ATE to an Air Force I-level (back-shop) repair facility

In today's world of constrained budgets, one of the problems the military faces is the challenge of trying to maintain organic maintenance capabilities. Historically, the US Air Force has desired to achieve an autonomous capability to maintain the equipment it uses. This has been achieved, traditionally, by setting-up three levels of maintenance: organizational; intermediate (back-shop); and depot. The I-level back-shops often utilize militarized automatic test equipment (ATE) and test program sets (TPSs) to test today's complex aircraft line replaceable units (LRUs). And even though this is still a cost-effective maintenance philosophy, it has become costly to develop militarized ATE. The Department of Defense (DoD) has been very active in trying to reduce the total ownership cost of ATE in the government inventory. One approach is to utilize commercial, instead of Mil-Spec, ATE. However, utilizing commercial ATE at an USAF back-shop is not without its tradeoffs and challenges as it represents a significant deviation from the way the USAF maintenance squadrons are accustomed to "doing business." This paper documents the current success story of replacing the legacy C-17 I-level ATE with a commercial ATE.     

Teaching old tricks to new dogs [automatic test equipment]

This describes why transferring test programs and fixtures from obsolete automatic test equipment (ATE) to new equipment are not as simple as it should be. No one would argue that technology has made major advances on test in the last 30 years. Today, speed, overall performance, computing power, and software tools are more sophisticated than 20 or 30 years ago, when the first ATE appeared. As these ATE now head for retirement and as the programs they support still have a long life to live, one would think legacy replacement with new ATE would be a simple task. Unfortunately, this is seldom the case. We realize that old ATE had a number of cards up their sleeves to deal with. For example, high voltage technology, lack of computer aided engineering (CAE) data, requirements for parametric tests, extensive usage of the guided probe, and many other aspects might be not so simple to be reproduced with modern, yet powerful, ATE. The paper shall identify the specific constraints involved with old technology and give examples of success stories where new ATE has been adapted to respond to the challenge. Paraphrasing (in reverse) and old saying, it is like "teaching old tricks to new dogs".     

Implementing reusable, instrument independent test programs in thefactory

Development of computer programs that control test sequences on Automatic Test Equipment (ATE) is costly and time consuming. Test Programs are usually written by specifying the instruments to be used in the ATE and the sequence of the setup and measurement parameters for these instruments. Reuse of test program software on other ATE is usually not possible without rewriting, revalidating and re-releasing the programs. This paper describes an implementation of a test program software development system and a standard of software runtime architecture used in our factories. The object-oriented development environment and its associated class libraries allow test programs to be written without knowledge of the ATE on which they will be run. Two main principles guided the design: the software architecture was based on recognized formal and industry standards; and our implementation used commercial off-the-shelf software products when possible. Emerging standards such as the IEEE-1226 (ABBET) as well as defacto industry standards including VXI Plug and Play have made our implementation possible. The current draft of the ABBET and P&P standards do not promote this instrument independence, but it is hoped that this will be added as the standards mature. Three immediate benefits are: cost savings that result from reusing validated test programs; cycle time reductions that result from concurrently developing test program software and ATE; and software defect reductions that result from using proven software     

DQI-NP application to the OutriderTM Tactical UnmannedAerial Vehicle (TUAV)

A wide variety of applications can benefit from integrated Inertial Navigation System/Global Positioning System (INS/GPS) technology. However, in many situations, the end user has a preference for a specific GPS receiver. Additionally, in most cases, the user does not desire to expend the time and money necessary to perform a custom INS/GPS integration, but instead wants a low-cost off-the-shelf solution. To address these applications, Boeing has developed the Digital Quartz Inertial Measurement Unit (DQI IMU)-Navigation Processor (DQI-NP) product as an extension of its Miniature Integrated GPS/INS Tactical System (MIGITS^TM) family of integrated INS/GPS products. This paper describes the DQI-NP and its application to the Outrider^TM Tactical Unmanned Aerial Vehicle (TUAV). The DQI-NP, as currently integrated into the Outrider^TM TUAV, is coupled with a custom Trimble GPS receiver combined with major embedded firmware modifications by IntegriNautics. In conjunction with differential GPS and ground based pseudolites, the overall system is intended to provide autonomous landing capability to the Outrider TUAV. DQI-NP provides an available, low-cost, commercial-off-the-shelf/non-development item (COTS/NDI) solution to a variety of commercial and military applications, of which the Outrider ^TM TUAV is an excellent example     

COTS based open systems for military avionics

The DoD has many acquisition programs that are aggressively implementing open architecture principles in new avionics systems. Since “open” is an unclear attribute, projects eventually give in to a point solution that has no flexibility to cost effectively keep up with rapid changes in technology. The Open Systems Development Initiative (OSDI) project utilized COTS products to study the feasibility of building an open system that has plug-and-play capabilities. Lessons learned from the AV-8B Open Systems Core Avionics Requirements (OSCAR) and the F/A-18 Advanced Mission Computers and Displays (AMC&D) programs clearly indicated that understanding the underlying interfaces is crucial to keeping the system as open as possible to take advantage of the rapid changes in technology. A matrix of Key Open Standard Interfaces (KOSI), called the KOSI matrix, was developed and an applicable standard was identified for each interface. A list of non-conforming interfaces was also identified and the use of extensions or wrappers was investigated in an attempt to comply with standards. Standardization, rather than optimization of such interfaces, was considered more beneficial. It became evident that, with the exception of ruggedization, there is no difference in the use of COTS products for either commercial or military systems. Performing a KOSI analysis helped identify the key interfaces and standards, thus enabling the OSDI system to be scalable, portable and interoperable. A good KOSI matrix provides a vehicle for clear communication and helps systems integration and technology insertion to be less painful than what it is today. It helps reduce time-to-market and provides guidance to systems engineers and vendors to keep the system open     

Development of a TPS reuse library using COTS tools

In the past, functional test requirements (FTR) or test requirement documents (TRD) and test program sets (TPS) were standalone items developed by individual engineers. In some cases, one engineer would write the FTR/TRD and another would develop the TPS. Commercial ATLAS FTRs are prepared in ARINC 616 and 626 ATLAS. Military TRDs are written in IEEE ATLAS 716 versions. Previous test reuse attempts have not been successful because additional software, like browsers, is required to support these efforts. It was difficult to justify writing new software; for example, browsers to manage the application software. Today, commercial-off-the-shelf (COTS) tools are in place to browse and view information from circuit diagrams to documents to source code. These tools can develop hierarchies to organize the information. These COTS tools are available throughout Boeing on many types of workstations and personal computers on every engineer's desk. This paper discusses how a reusable test library (RTL) is being developed using commercial-off-the-shelf (COTS) tools, such as Mosaic, to address commercial and military test applications. It describes each of the tools and the process to develop TPSs using the reuse library. It defines the metrics and benefits achieved     

Analysis tools for the evaluation of maintenance software

Test packages written for built-in test (BIT) and mobile automatic test equipment (ATE) systems for the forward support of electronic and thermal imaging equipment used by the British Army are currently scrutinized and subjected to objective tests by test package evaluation and acceptance teams (TPEATs) before being accepted for field use. This is a time-consuming and costly exercise that can result in the rejection of unsuitable software. The result of such rejection on equipment logistics is for reaching, since the hardware will enter service without adequate maintenance support. In an attempt to address this problem a suite of programs aimed at assisting the verification and validation activities of the TPEAT at every stage of the software life cycle from requirements analysis through to testing and acceptance is being devised. The development of these tools is discussed     

Automated testing

Since the DoD was the leader in incorporating transistors, ICs and embedded processors, they also were on the forefront in developing automatic test equipment. The term automatic test equipment (ATE) encompasses all phases of computer controlled testing. It is based on the integration of instruments, computers and software. These systems generally include five basic elements: control, stimulus, measurement, switching and software. A special interface device or interface test adapter connects the unit under test (UUT) to the ATE. Test program software connects the ATE to the appropriate UUT test points, programs the input stimulus and monitors the output response     

The benefits of using ATE systems in the testing of printed circuitboards

An industry-based pragmatic review is provided of the economic and product-quality consequences of automatic test equipment (ATE) usage in printed circuit board testing. The company selection process, the nature of the industrial participants, and the data collection process are described. The benefits obtained by users are identified. It is demonstrated that the use of ATE systems does result in definable economic and quality-level benefits     

ATE综合校准系统的软件设计及实现

通用自动测试设备（ATE）的测量准确性、可靠性会直接影响飞机综合保障的质量,因此,对此检测设备进行全面有效的测试校准,是确保测试系统完成任务的关键。为了保障测试数据准确可靠和量值传递统一及实现现场的系统性校准工作,本课题以通用自动测试设备为对象,建立了一套基于虚拟仪器技术基础上的综合校准系统。本文对系统的软件结构设计进行了分析和设计,以LCOD原型生命周期为基础,使用了面对组件的设计模式,设计和实现了软件功能,使得该系统具有一定的兼容性和可移植性,并且为扩展留下了接口,同时保证了校准数据的可靠性和精确性。