BACK GROUND OF INVENTION

I) Brief about DITMCO Automatic wiring analyzers

DITMCO stands for "The drive-in theatre manufacturing company". DITMCO is a trade name for a range of machines called automatic wiring analyzers.

Before automatic wiring analyzers, we would check for wiring continuity/Insulation resistance by hand. This was very time consuming and faults were missed as you could only check Insulation to earth not to all other wires on the aircraft.

DITMCO wiring analyzer is a new concept. It is a total machine interface system and connected to PC/Printer. All the test reports can be printed and preserved as a hard copy for inspection and soft copy in the hard disc for future reference.

The DITMCO wiring analyzers verify continuity, insulation/resistance, hi-pot and even perform functional testing of relay chassis, control panels and other assemblies with components. The DITMCO is capable of performing the following functions

• Circuit continuity tests for open circuits
• Insulation resistance verification for short circuits
• Dielectric breakdown (hipot) tests
• Resistor tests
• Relay tests
• Diode tests
• Capacitor tests
• Switch and circuit breaker tests

The DITMCO is made up of the following basic components.

1. Test Station: The analyzer system used to test products & usually consists of three parts: Computer Station, Controller, and Switching System.

2. UUT: Unit Under Test, any product that will be tested by the analyzer.

3. Termination: A point on the analyzer that can be connected to the unit under test (UUT). Also referred to as a Switching Point.

4. Adapter Cable: Custom cabling that connects the UUT to a switching point/termination.

II) Brief about DITMCO Automatic wiring analyzer available at Aircraft Division. HAL
HAL, Aircraft division loom shop has so far under taken fabrication of wire harnesses for a variety of programs such as for the Kiran aircraft. Jaguar aircraft, PTA UAV, etc. During Jaguar build for testing of electrical integration, cable testing station (CTS) was used in Loom Shop and it was manual interface system. This system used to take 2-3 days for cable testing and was not linked to the computer to take print out of test results. The CTS system has become obsolete.

The DITMCO wiring analyzer Model 2115-S17-0560 was procured and installed in HAL Aircraft Division Loom Shop in 2008 during the induction of the Hawk Mk-132 License build programme. The testing of 32 types of panels/junction boxes and 3 types of pylons is carried out by the Model 2115-S17-0560. The testing of these units is very critical requirement as per BAE system process. It involves mainly the checks on Insulation, Continuity, Isolated Points, AC/DC Dielectric and Voltage/Current. The custom made test programs & adapter cables required to test the HAWK pylons; electrical boxes and panels were provided by M/s. BAES.

DITMCO Model 2115 is a computer-controlled analyzer system that is used primarily for making tests on electronic products. It can perform resistance and insulation tests on a unit under test (UUT) with Standard Measurement Unit (SMU) or Single Board Comparator (SBC). Under program control, the Model 2115 performs the following functions:
1. Selects the test instrument and sets the pass/fail limits.
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2. Selects test points on the UUT via switching system and connects the selected test instrument to the test points.

3. Receives pass/fait data from the test instrument and routes data to the applicable Input/Output (I/O) device (such as screen and/or printer). The basic configuration of Model 2115 is a Master Switching Unit (MSU) with 1,000 points of Series 17B switching and Pentium-clone based microprocessor. i Control signals from the computer are routed to the Master Switching Unit (MSU) via an Enhanced Parallel Port (EEP). These signals select the required device. If the device is switching, control signals are routed via the Analyzer Controller Board terminal selector logic to the switching system. These signals select the applicable relay. The SMU or SBC supplies a stimulus to the UUT via the terminal selector and switching system. A measurement is then made and the test results are routed back to the computer via the EEP. Test results are printed at the local printer or re-directed as specified by the test programmer. The analyzer is included with standard DIT-MCO software applications that include TestExecutive® and TestEdit®.

Test Executive

TestExecutive is a comprehensive test control software tool that helps to run DITMCO test programme. The software environment uses Internet Explorer, Microsoft Windows operating system, toolbars and menus. Using TestExecutive allows large operations that test many different products. The following are the Test Executive features:

1. Increased memory
2. Enhanced manual entry mode
3. Long file name
4. Quick test programme start up
5. Active mode display
6. True graphical user interface(GUI)
7. Browser interface
8. Customised printed error reports
9. Scrollable error display
10. Remote viewing of test system operation

TestLink

The DIT-MCO TestLink software family provides all the tools you need to make testing applications, from data preparation to statistical process control, fast and efficient.

TestEdit is part of the DIT-MCO TestLink family. The TestEdit is a comprehensive programming tool that helps you create and edit the files needed to verify your products. Files generated by this program include Address Correspondence Table files (ACT files). Address Correspondence Exception files (ACE files) and Test files.

The TestLink Launcher is a top-level application that makes it possible to launch and operate all of the applications within the DIT-MCO TestLink software family.

Ill) Customization of the DITMCO Model 2115 for the F/A-18 Wire harness program for M/s. Boeing IDS. St. Louis During 2008 HAL received a Purchase order from M/s. Boeing and Boeing supplied Build to Package Documents for manufacturing of 27 Cable Assemblies of FA-18 Aircraft EFG Variants. As part of requirement of RFP HAL needed to manufacture and Test the 27 Cable Assemblies per Build to Package Documents and. Process Specifications. The Cable Assemblies manufactured by Aircraft Division, HAL (BC) for Boeing IDS FA-18 Aircraft EFG Variants needed to be tested for Continuity and Megger.

Thus Aircraft Division, HAL (BC) with the experience of working with the DITMCO on the HAWK program has Designed and Manufactured DITMCO Adapter Harness & Developed DITMCO Test programs for 27 Cables Assemblies of FA-18 Aircraft EFG Variants.

DESCRIPTION OF THE INVENTION

The invention mainly involves Automated Testing of FA18 E/F/G variants aircraft Cable Assemblies:-

1) Design of the DITMCO Adapter Harness - Interface between the DITMCO & Cable Assembly.

2) Development of the DITMCO Test Programs - Individual Test Program for each Cable Assembly as per Boeing IDS Process Specification.

DETAILED DESCRIPTION OF THE INVENTION

1) Design of the DITMCO Adapter Harnesses

The purpose of using an adapter harness is to interconnect the DITMCO to the Cable Assembly under test. 16 Types of adapter harnesses have been designed and produced for Automated Testing of FA18 E/F/G variants aircraft Cable Assemblies.

Each type of adapter harness Part Number is formatted as Aircraft Project Code (First 3 Letters), DITMCO Connector Number Block (4-15 Letters) and SERIAL NUMBER (Four numerals taken in numerical order from the DITMCO number register, 16-19 Letters).

Example 74A 026 027 028 029 0013

[AIRCRAFT PROJECT CODE] [DITMCO CONNECTOR NUMBER [SERIAL NUMBER] BLOCK]

Details of the Adapter Harness Part Numbers

1. 74A 000 0010001
2. 74A 002 003 0002
3. 74A 004 005 0003
4. 74A 006 007 0004
5. 74A 008 009 0005
6. 74A 010 0110006
7. 74A 012 013 0007
8. 74A 014 015 0008
9. 74A 016 017 0009
10. 74A 018 019 0010
11. 74A 020 0210011
12. 74A 022 023 024 025 0012
13. 74A 026 027 028 029 0013
14. 74A 030 031032 033 0014
15. 74A 034 035 036 037 0015
16. 74A 038 039 0016 ]

Inverse Connectors with Straight Back Shells of FA18 E/F/G Cable Assemblies and Inverse DITMCO Connectors were identified. 22 AWG wire, TMS Sleeves, Rilsan Sleeve, crocodile clips and accessories were identified for design and manufacture of DITMCO Adapter Harness. The types & quantities of material used are listed below.

i i 1 1 1

Concept of multiple adapter harness usage on individual cable assemblies depending on cable assembly connector type was adopted to make automated testing more economical. Any cable assembly can make use of the above adapter harnesses subject to the fact that the cable assembly uses inverse connectors used in the adapter harness.

DITMCO Adapter Harness length of 5 Meters was planned. Documents such as Drawing Sketch, Material list and interconnections were built for manufacture.

2) Development of the DITMCO Test Programs DITMCO Test program involves development of two programs

1. ACT FILE
2. TEST PROGRAM

1. ACT FILE is a test instruction to specify an analyzer address. Three methods can be used to address the DITMCO switching address

1. Address Format
2. PLL Format
3. Combination of the address format and PLL format.

Product Language Lookup (PLL) method is adopted to address the DITMCO. PLL Format auto generates Machine Language address file with .UT Extension. The advantages of this method are easy to write the test address in the test program and error rectification by the user.

Example of a PLL Address

0-30 72P-B001A 1

DITMCO CONN UUT CONN PIN#
S/W ADDRESS
2. Test Program has been developed to test Continuity and Insulation test per test parameters called for in Boeing IDS Process Specifications. Wire ids are written after each test line to make it user friendly for easy error identification.

Test points are identified from the Build to Package documents provided by Boeing IDS.

Example of a test line

F-28P-B018 A Switching Address From

C-52P-B023 85 Switching Address To

# [CHECK WIRE C0000005069A Wire ID

Details of the Test programs developed.

1. 74A922203-1004
2. 74A922203-1701
3. 74A922204-1002
4. 74A922205-1004
5. 74A922206-1009
6. 74A922206-1509
7. 74A922206-1703
8. 74A922206-1704
9. 74A922206-1951
10. 74A922208-1001
11. 74A922208-1701
12. 74A922209-1001
13. 74A922209-1701
14. 74A922210-1002
15. 74A922210-1701
16. 74A924215-1003
17. 74A924215-1701
18. 74A924218-1004
19. 74A924218-1701
20. 74A924219-1005
21. 74A924219-1701
22. 74A925215-1006
23. 74A925215-1701
24. 74A925218-1005
25. 74A925218-1701
26. 74A925219-1005
27. 74A925219-1701

CLAIMS

I claim by use of DITMCO Adapter Harnesses and TEST Programs for FA-18 Aircraft EF6 Variants (27 Cable Assemblies).

1. The Design of DITMCO Adapter Harness is universal in nature; it enables the manufacture of DITMCO Adapter Harness globally.
2. The Developed TEST Programs are Compatible on All models of DITMCO Automated Test i Equipment and also compatible with other vendors Automated Test Equipment which can run DITMCO Test Programs like MK TEST System, (UK).

3. With 16 DITMCO Adapter Harness and 27 DITMCO TEST Programs, 27 Cable Assemblies of FA-18 Aircraft EFG Variants can be automatically tested for Continuity and lnaula\ion Test.