SPEEL PRAHA Ltd.

The project was realized thanks to the financial support from state resources via Ministry of Industry and Trade.

Present situation of the equipment of helicopters in CR with regard to flight recorders is the following:

• they are equipped with no flight recorder
• they are provided with flight data recorder SARPP which do not meet current service requirements due to it's opto-mechanical recording method and limited choice and accuracy of measured parameters
• system SARPP is replaced by flight data recorder with solid-state memory and eventual extension by Global Navigation Satellite System GPS. The original sensor network is kept (i.e. the original sensors and their number)
• in the system BUR 1, the mechanic tape recorder is replaced by solid-state memory flight recorder

The universal central measuring unit designed in this project meets in particular the compulsory (and some recommended) requirements on recorded parameters' accuracy and resolution for single helicopter categories

The types of sensors are specified by producer of the helicopters' engines (e.g. Mi-24's engine TV3-117VMA) or by the built-in sensor network in the other case. Extending the network with other sensors can be settled with single customers which will ask for additional modernization of the flight deck recording system. The Basic Technical Requirements ZTP in accordance to CSN EN ISO 9001 : 2000 standard if required by the customer are met, as well.

HDAU's conception represent an open system. It's design is based on LDAU (basic version) or more precisely on FDAU-B (an extended version meeting requirements on systems of HUMS type). The universality of the system lies in the option to combine the composition of the boards according to the demands of the customer and in the option to programm the characteristics of the boards without interfering with board hardware.
HDAU collects the data about chosen flight deck systems and parameters and is designed to perform the following functions:

• process the selected analog and discrete signals
• RT of the avionics system
• BC of the system bus 1553B
• receipt of data from ECU
• data preparation for record to CVFDR
• vibration monitoring in order to determine the stress to the rotational parts and the load on the airframe
• process the above stated data with suitable designed algorithms and save the result of the analyses in the central unit's internal memory.

User Software Development

The objective of this phase was to integrate the data and information acquired from helicopter's flight deck systems and engines into unified analysis system PANDA by company SPEEL PRAHA Ltd. That enabled to process and present data by standard PANDA modules. The description of the integration is listed in these PANDA manuals:

CALB

analog parameters calibration

EDIT

structure scheme describing the layout of measured parameters in channels

LOAD

carry over the data from flight deck to analysis station

VIEW

graphical and table presentation of measured data

COMP

design user analyses and assess data files in accordance to this analyses

Flight Verification of the Cental Measuring Unit

According to the original plan, the parameters of the central measuring unit should have been verified in the operational flight environment directly on the helicopter flight deck after finishing basic laboratory tests. Because of the hazy delivery situation of the helicopter Mi-171Š and Mi-35 from The Russian Federation, the verification date was moved. This was the reason for choosing other alternative how to meet the requirements of this phase. In the same time, we were asked by an foreign customer to lay before a proposition on a flight data collection and record system for their supersonic jet aircrafts. A part of our proposition had to be a demonstration of the system on the flight deck of a chosen two-seat aircraft. Considering the little time we had for the project, we thought aboat using HDAU as central measuring and control unit.

With respect to the very limited room for the central unit, we could not use the cental unit in the original design but we had to modify it for the given assignment. We utilized the circuit design of analog and discrete inputs including the main processor board. Because of the fact that the aircraft employed communication bus of type ARINC 429, we replaced the original communication card 1553B by the newly designed modul ARINC 429.

At the same time, we were solving the matter of choosing the right sensors. In this matter, we focused on new perspective sensors which would have been employable in both aircrafts and helicopters. We chosed two types of sensors from prestigious producers designed for OEM applications and we successfully employed them on the flight deck after laboratory examination.

First of them is three-axis accelerometer by Silicon Design company that is used to sense acceleration along all three aircraft axes. We used the sensor as the basic building block of the newly designed Accelerometer SACC 2440. We have processed the output signals from the sensor by active low-frequency filters of 4th order which adjust the product's frequency characteristics and sensitivity.

The second sensor is the position sensor by Positek company. It is a contactless sensor based on the Hall's effect embedded in sturdy aluminium alloy case with IP67 cover.

We completed several ground engine tests, rolling, and two test flights in order to test these components. Evaluation of both flights demonstrated that the designed system fulfil the posed requirements.

Therefore, we can claim that the above stated flight verification gives us right to assume that the central unit HDAU will fulfill requirements for flight deck service.

Functional exemplar of the cental measuring unit HDAU

The central measuring unit FDAU-F7 for FT-7P aircraft was developed from the Universal Central Measuring Unit HDAU

The central unit FDAU-F7 was situated in the front part of the FT-7P aircraft (in the right)

The project was realized thanks to the financial support from state resources via Ministry of Industry and Trade.

FAMOS

The project's goal was the development and production of a device prototype for monitoring airframe load spectrum and so extend the service lifetime. The airframe service lifetime depends mainly on the construction material attributes. The material attributes are affected by external effects and are generally worsening in time. Therefore, FAMOS scan the effects of material fatigue owing to mechanical load during aircraft operation.

Program FAMOS support implementation in these phases:

• sensor setting (number, type, and location determination)
• sensor signal lay-out and sampling
• determination of constants characterizing the sensors, construction materials, and lay-out
• debugging the fatigue computations OFF-LINE and their implementation as an application running on FAMOS-A unit
• the possibility to create object damage and sensor usage databases with purpose in system management and service
• databases administation

FAMOS-A Unit

FAMOS-A is designed as a modular system with open architecture which consists in requested configuration of 4+1 modules: power supply module, processor module, SCSI bus module, strain-gauge bridge and accelerometer signal process module and removable memory module (MMC) with SCSI FLASH disk.

The power supply module generates the needed supply voltage from the flight deck supply network 28V DC via DC-DC voltage changer. The voltage changers are preceded by transient filter circuits (absorb voltage spikes > 50 V from the supply network), hold-up circuit, EMI filter circuit (filtration of disturb signals of DC-DC voltage changers emitted into the flight deck network) and other auxiliary circuits. The whole FAMOS-A system is controlled by the processor module with PowerPC processor. Parts of the processor module are RAM memories (SDRAM and NvSRAM), a Boot FLASH memory with operating system loader, a lokal Flash Disc containing the operating system and all aplications, Ethernet bus controller for 10 Mbps / 100 Mbps transfer speed, double serial port RS232 / RS422, cPCI bus controller, and other auxiliary circuits. SCSI bus controller module contains interface Ultra2 SCSI with maximal transfer capacity 80 MB/s. SCSI Flash Disc is connected through the SCSI-LVD interface located in the removable memory module MMC. The used interface SCSI allows the MMC exchange in the ground workstation without necessity for switching off the supply voltage following by the restart of the operating system (hot swapping).

Strain-gauge bridge and accelerometer signal process module provides input filtration of eventual VF disturb component, programmable amplification, anti-aliasing filtration, A/D conversion. Digital data are further processed by signal processor which allows implementation of optional digital filtration of measured signals. The measured and processed values are transfered from the signal processor through the double-gate memory and cPCI bus bridge into the central processor module and written into the removable memory module consequently. The strain-gauge bridge and accelerometer power supply circuits are parts of the module.

Removable module MMC

MMC contains only SCSI Flash Disc and connector adapter. The needed disc capacity for data files has not been estimated yet but, considering the development in the area of FLASH memories and hard discs, the capacity of MMC will never be the limit factor for FAMOS-A system. We presently use 13 GB capacity disc for functionality verification.

Removable module MMC

A PC with LVD SCSI interface and MMC-BAY adapter are required for connecting MMC to the PC. In a desktop computer, it is advisable to use the internal PCI card with SCSI controller and in a laptop, it is possible to use PCMCIA card with SCSI interface controller or USB to SCSI adapter. Since MMC in MMC-BAY works as standard SCSI device, it is possible to connect several adapters MMC-BAY or other SCSI devices to one bus.

Program FAMOS

Program uniquely determine history of load of aircraft or tested objects during their operation. It can be used to control load of each aircraft and plan exchange components that truly used up their service life (landing gear, wings, etc.). It eliminates the influence of the human factor that usually conceal the exceeding of aircraft limit. Therefore, the program records all program operations and they could be supplied on demand. This all contribute to the increase in the security of operations. Program FAMOS can be used not only for aircraft applications but even in strength test facilities.

The Final Version of Firmware and Software

In this phase, the final shape of flight deck firmware and software was completed. The overview of basic firmware parts:

• the VxWorks operating system allowing running other applications
• collection of operating system drivers making possible the access to:
  • internal FLASH disc
  • A/D converter module that process signals from the strain-gauge bridges and accelerometers
• removable memory medium MMC
• measure and record the instant values of the strain-gauge bridge and accelerometer signals into a file in MMC that has structure defined in a definition file
• pass measured values of the strain-gauge bridge and accelerometer signals to other applications running in VxWorks operating system

The overview of basic software parts (flight deck parts):

• read constants characterizing the used strain-gauge bridges and accelerometers (calibration coefficients and type)
• read computing constants characterizing location of the strain-gauge bridges and accelerometers
• process input parameters of the strain-gauge bridge and accelerometer signals using the four-point algorithm for the ON_LINE computation of the spent aircraft airframe service time.
• record the current flight evaluation results
• cumulation of all flight results where the instant value of damage to the aircraft airframe is always available

User Software Development

The user software contains program modules working in a OFF_LINE mode at the ground workstation. The first part of the program is intended only for evaluation of data from flight deck system FAMOS-A and the second part is optional PANDA software

FAMOS-A evaluation modules:

The overview of basic functions of LOAD_FAMOS module

• browsing and displaying the file system structure of MMC unit
• saving the measured data from MMC unit to PC without processing (for archiving)
• transcript selected data files from MMC to PANDA system data file format (file format D); this function enables consecutive processing and evaluation of D files by other PANDA system modules (VIEW, EDIT, COMP)
• writing files on MMC unit (that means files which are required by FAMOS-A, DEFPAR definition file, the xxx.CNS file of computation and test constants)
• deleting files on MMC
• completing the D data file with other service information (pilot's name, etc.)

The overview of basic functions of FAMOS module:

• process data from D file using algoritmus for the computation of the spent aircraft airframe service time (an alternative mean of computation in the case of on-line application program breakdown)
• saving results of flight evaluations into the database in the form of one database sentence; the history of the tested place (aircraft) about the spent airframe service time is so created
• database export and import
• selected sentences deletetion
• manually insert sentences into the database (assurance of continuity of aircraft damage history when no record is at hand)
• setting up master discs for each aircraft
• matrix archiving and restoring from the master diskette
• view the selected output configurations on monitor
• print selected protocols
• export selected protocols to a *.txt of *.css file
• batch file processing
• create and upkeep a database of constants which characterize used sensors and their location at the tested object (an aircraft)
• the creation of collections of these constants (file for on-line application)

Optional modules from PANDA software

The overview of basic functions of VIEW module:

• graphical presentation and data analysis (searching for maxima, minima, etc.)
• change of time and parameters scale
• view of the parameters in the form of graph or table (color, units, axis, and choosen parameter levels are optional)
• export the data to a file
• view the aircraft silhouette in space
• zoom mode

An overview of basic functions of EDIT module:

• create, edit, save, and read the definition, data, and calibration files
• definition of mathematical analog and double-valued parameters
• view the information header and data block
• edit the layout of parameters in channels

The overview of basic functions of COMP module

• create and edit user analysis
• batch data file and analysis process

Program LOAD_FAMOS

This module allows transcript of data recorded on the flight deck by FAMOS-A system into data files, whose format agree with requirements of PANDA system (software system for evaluation FDR flight data recorders), and so they could be processed by other PANDA modules, e.g. graphical evaluation and data analysis (VIEW), view and edit selected PANDA system files (EDIT e.g. DEFPAR files), create, edit, and run user analysis (COMP). These modules also allow to export data into various formats and then to process them in other applications (EXCEL, etc.).

FAMOS-A Unit

MMC unit

MMC BAY read unit and PC

Program FAMOS

SPEEL PRAHA Ltd. offers several PANDA software packages designed to evaluate records from FDR flight data recorders for various users according to their needs and configuration of the recorders on their aircrafts.

For the evaluation, the user needs only portable computer (notebook) or removable memory module PMU, which read data from the aircrafts' recorders, and the selected PANDA. package. It is possible to provide also this notebook or recommend it's type. The costs of the notebook or PMU are not included in the costs of the packages. Beside the listed packages, it is possible to choose and buy other modules of PANDA system (e.g. TRACE, FRAME159, ENG410, etc.) and achieve so the full and comfort evaluation of flight records.

1. PANDA BASIC

   - this version is designed for customers that possess small number of one-type aircrafts equipped by an one type of the FDR recorder (e.g. the L410 aircraft with the FDR59B-L recorder). It provides basic evaluation of flight records and supply these functions:
   • read the data from an one-type FDR recorder into the data file (LOAD_FDR module)
   • display and monitor the recordered parameters from the data file and their basic evaluation (VIEW module)

   the part of the delivery could be the communation cable for connection between the recorder and the computer (LOAD-V)

   The cost of PANDA BASIC version is very advantageous and is 39 500 CZK (LOAD_FDR, VIEW, LOAD-PC).

2. PANDA CLASSIC

   - this version is designed for customers that possess several types of aircrafts equipped by various types of the FDR recorders (e.g. the L410 aircraft with the FDR59B-L recorder) and the Mi-17 helicopter with the FDR39HGM recorder). It provides basic evaluation of flight records, archiving and supply these functions:
   • read the data from various types of FDR recorders into the data file (LOAD_FDR module)
   • display and monitor the recordered parameters from the data file and their basic evaluation (VIEW module)
   • the data files archiving (MANAGER module)

   the part of the delivery could be the communation cable for connection between the recorder and the computer (LOAD-V)

   The cost of PANDA BASIC version is very advantageous and is 195 000 CZK (LOAD_FDR, VIEW, MANAGER, LOAD-PC).

3. PANDA STANDARD

   this version is designed for customers that run large number of aircrafts of various types and maintain the aircraft themselves including the operation verification and calibration of FDR recorders. It provides the verification of the FDR operation, the calibration of the FDR system, complete evaluation of the flight records and supply these functions:
   • read the data from a FDR recorder into the data file (LOAD_FDR module)
   • read the data from the PMU memory into the data file (LOAD_PMU module)
   • display and monitor the recordered parameters from the data file and their basic evaluation (VIEW module)
   • the data files archiving (MANAGER module)
   • verify the clearness of the FDR system and read the parameters on-line (REAL_FDR module)
   • calibration of FDR system analog sensors (CALB_FDR module)
   • verify the FDR operation (REAL_FDR and CALB_FDR modules)

   the part of the delivery could be the communation cable for connection between the recorder and the computer (LOAD-V)

   the part of the delivery could be the communation cable for connection between the PMU memory and the computer (PMU-PC)

   The cost of the PANDA STANDARD version is set according to it's particular configuration.

4. PANDA SERVIS

   this version is designed for customers that run large number of aircrafts of various types and maintain the aircraft themselves including fault finding, operation verification and calibration of FDR recorders. It provides verification of the FDR operation, calibration and modification of the FDR system, complete evaluation of the flight records, modification of various types of files of PANDA system, fault finding and supply these functions:
   • read the data from a FDR recorder into the data file (LOAD_FDR module)
   • read the data from the PMU memory into the data file (LOAD_PMU module)
   • display and monitor the recordered parameters from the data file and their basic evaluation (VIEW module)
   • the data files archiving (MANAGER module)
   • verify the clearness of the FDR system and read the parameters on-line (REAL_FDR module)
   • calibration of FDR system analog sensors (CALB_FDR module)
   • verify the FDR operation (REAL_FDR and CALB_FDR modules)
   • the evaluation of records from FDR after the crash (CDRU unit)
   • create and modify the various types of files of PANDA system (EDIT module)
   • define events using special compilator and search for them in data files (COMP module)

   the part of the delivery could be the communation cable for connection between the recorder and the computer (LOAD-V)

   the part of the delivery could be the communation cable for connection between the PMU memory and the computer (PMU-PC)

   The cost of the PANDA SERVICE version is set according to it's particular configuration.

The airborne data server AirMiS allows transfer all data between the ground workstation and the aircraft using just one removable memory unit MMC (Mass Memory Cartridge). The data files, which will be on the flight deck made accessible to the avionics systems (e.g. airborne computer) via communication buses, are written into the MMC before the flight. During the flight, the avionics systems can not only read data from MMC but also write data into MMC.

AirMiS is designed as a modular open-architecture system which enables it's easy modification along the customer's requirements.

The example configuration and usage of AirMiS system for two-seat multi-purpose jet aircraft L159B:

• recording of audio and video signals:
• record the HUD (Head Up Display) image
• record the MFD (Multfunction Display) image
• record sound from the airborne communication system (intercom)
• record all data transfered by the pair of avionics buses
  MIL-STD-1553B
• record PCM data from the measuring systems
• record the flight data from airborne diagnostic system AMOS-B - communication via the MIL-STD-1553B bus
• the MMC memory unit is made accessible to the airborne computer IAP (Integrated Avionics Processor) via the Ethernet bus especially to transfer data (Mission Planning Data) needed to carry out the planned mission
• the MMC BAY block, which provides the ground computer fast access to the MMC removable memory unit, is added to the ground workstation
• the software for the preparation of mission (Mission Planning) and following evaluation of the carried-out mission (Mission Debriefing) is a part of the ground workstation

Basic advantages of usage of the airborne data server AirMiS on L159B:

• integration of all data into just one memory medium
• replacement of the pair of the videorecorders
• replacement of the data transfer system which transfers data to airborne computer
• replacement of the flight data reader

• the program modules at ground workstation has access to the complete database needed for the evaluation of the carried-out mission; it is therefore possible to make complex evaluation like: what was the mission task, what has been accomplished, and how was the mission executed

Aerometric central unit ADC-159

ADC-159 is designed to measure the barometric height, the indicated airspeed, and the Mach number. The measured data are available in the digital form (RS-422 / RS-232C buses) and in the analog form (voltage outputs).

ADC-159 also generates five output signals that are controlled by algorithms evaluating if the limits of the measured parameters are exceeded. The precision of the barometric height agree with RVSM requirements (Reduced Vertical Separation Minimum).

ADC-159 was developed as a reserve measure areometric central unit for the L159B aircraft.

Electronic tachograph RRM9

Tachograph RRM9 is continuation of tachograph serie RRM; in comparsion to RRM8, it is possible to plug in larger number of output digital signals (max. 48) and has a protection system MATRA. Detailed information is presented at the appropriate pages.

Program module EngState

EngState module is designed to on-line reading and following evaluation of chosen parameters in the aspect of the engine M601 power characteristics. The parameters are read from the FDR59B-L flight data recorder installed on the aircraft L410UVP. It is neccessary for the correct operation to measure the speed of the generator and the propeller, the temperature of the turbines, and the twist moment.

Program module LOAD_FDR

The LOAD_FDR module is designed to service and maintain the FDR recorders by SPEEL PRAHA Ltd. company. It's main task is to read and transfer data and service information from FDR recorders into the ground unit GSU (Ground Support Unit) or into the stacionary part of GEE (Ground Evaluation Equipment).

Program module CALB_FDR

The CALB_FDR module is designed to control and maintan the FDR recorders by SPEEL PRAHA Ltd. company. It is used as means to create and maintain calibrations and aircraft service information including writing the information into the FDR.

Program module REAL_FDR

The REAL_FDR module is designed to control and maintan the FDR recorders by SPEEL PRAHA Ltd. company. It enables to display the values of the selected parameters beeing recorder into the FDR recorder and their location on measure channels while on-line. The measured values can be viewed both in bit form (binary, hexadecimal, decimal) and in physical units.

Program module FrameCalb159

The FrameCalb159 module is designed to compute the calibration constants used to determine the physical values of strain from the strain gauges located on the flange of the main wing rib and in the fuselage wing spar of the L159 aircraft. The computation is realized on grounds of the evaluation of the flight data recorded by the AMOS monitoring system's recorder.

Program module TRACE

The TRACE module (for PANDA_WIN only) serve as the graphical interpreter of the flight data read from the PANDA sytem D data files. Data files has to contain data about the latitude and the longitude, the values of the angle of sight (HEAD), pitch, roll, and the altitude.

TRACE basic functions:

• display several aircraft profiles simultaneously
• display the flight trajectory in 2D and 3D view
• display the latitude, longitude, and basic flight parameter values
• superposition of the 2D map and the 3D relief of the landscape
• replay the flight forward and backward with various speeds
• tools to measure distance between chosen points (trajectory points, aircrafts, points in the landscape, etc.)
• possibility to save the chosen parts of the flight trajectory into a file

By this date, the tests of the Aircraft Monitoring System AMOS-B for the L159B aircraft was successfully finished.

The AMOS-B for two-seat jet aircraft L159B is designed to:

• gather, process, and record information about selected airborne systems of the two-seat jet aircraft L159B with the goal to offer the pilot information about the instant aircraft situation including warnings when the limit values are reached
• watch and monitor the load on the airframe in the long term
• record and protect the data designed to evaluate the air crashes
• watch and monitor the health state of the pilot
• guide the operator (i.e. the pilot or an engineer) during a preflight preparation of the aircraft using the sequence of defined tasks
• display a help during evaluation of critical events like tools for effective usage of the data recorded during the pilot's training

The difference from AMOS system for L159:

• different philosophy and construction of the system blocks
  AMOS-B
• large saving of cabling thanks to the location of the blocks on the aircraft
• communication between the AMOS-B blocks along the MIL-STD-1553B bus
• important increase to the number of analog and digital parameters
• larger amount of messages displayed on MFD display
• more detailed monitoring and evaluation of the load on the airframe
• record values of monitored paramaters and another information for at least 12 hours into the protected memory
• record two audio channels in length 120 minutes into the protected memory

On 3rd October 2003, the consolidation of the VZLÚ-SPEEL Ltd. and the SPEEL PRAHA Ltd. company was executed. The grounds for the consolidation is to concentrate the production, development and trade activities of both companies and so strengthen the position of the succession company.

In case of any questions, call number 286923619 or 286923633-34

In the days of 14th to 22th June 2003, the international exposition Paris Air Show 2003 - Le Bourget in Paris aimed at the presentation of aerospace weapons and aircrafts. The SPEEL PRAHA Ltd. company had presented there:

a collection of the FDR flight data recorders for various aircraft types including ground devices for reading data

the MDAW159B evaluation workstation for mission planning and debriefing

the AMOS–B monitoring system for the L159B aircraft, the airborne data server AirMiS and the aerometric central unit ADC–159