C-130 Modernization Experience – Integration of Digital Engine Instrument Display System (EIDS)

C-130
Modernization Experience –
Integration of Digital Engine
Instrument Display System (EIDS)
Presented By:
Tan Yen Ping
Senior Manager, Military Business
Aerospace
Land Systems
Electronics
Marine
Performance FY2010
S$1,871m
S$1,506m
S$1,389m
S$1,044m
Staff Strength
8,317
6,879
5,187
1,863
Maintenance, refurbishment, modification &
customization of commercial and military aircraft
Military C-130
Commercial L100
Commercial Aircraft
C-130
One-Stop Center
Component Overhaul
> 29,000 C-130 components
to-date
T56 Engine Overhaul
221 of T56-A-15; 45 of T56-A-7
to-date
Airframe
support
136 of L382 ;
383 of C-130
aircraft svc todate
C-130
Customization
& Design
Parts Support
Landing
Gear
Support
At the RSAF Open
House 2011
Prototype Testing Experience
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Test Instrumentation
Ground Acceptance Test
EMI/EMC Test
Flight Acceptance Test
Test Instrumentation
Collects data during ground and flight to facilitate post flight investigation of
observations and off-line evaluation of systems’ performance
Airborne Instrumentation System installed
Ground Test
Ground Acceptance Test prepares the aircraft for Flight Test
TCAS & Mode S
Transponder Test
Air Data System Test
Engine Analog vs Digital Display
check
Engine Instrument Display
System Integration – Engine
Run Check
EMI/EMC Test
Comprehensive EMI/EMC measurement gives assurance of RF components
co-existence and survivability; hazard effects of EM radiation on Personnel,
Ordnance and Fuel in the new RF environment
•
•
•
•
•
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Antenna coupling measurement
Receiver susceptibility test
Interoperability Test
Conducted Switching Transient Test
HERP, HERO & HERF Field Strength
Measurements and HERO Stray voltage
(SV) checks on Air Refueling and Fire
Extinguishers Electro-Explosive Device
(EED)
Flight Test
Flight Acceptance Test verifies systems’ performance in flight
High Speed Run
Functional check Flight
Handling Quality Check
Performance check Flight
EIDS Integration
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•
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EIDS System Overview
Test Objectives
Test Setup, Methodology
Conduct of Test
Summary of improvements
From Analog To Digital
Engine Instrument Display System
EIDS Overview
Engine Instrument Display System
• Engine Interface Unit (EIU)
– TSO certified
– RTCA DO-160D
– 9 engine parameters:
• Torque
• RPM
• Turbine Inlet Temperature
• Fuel Flow
• Engine Oil Temperature
• Engine Oil Pressure
• Gearbox Oil Pressure
• Engine Oil Quantity
• Oil Cooler Flap Position
Two independent EIUs
with dual independent
channels
Engine
1
Torque
Tachometer
TIT
Fuel Flow
Oil Temp
Oil Press
Oil Qty
Oil Cooler Flap
2
3
4
EIDS Architecture
Engine 1
Engine 2
Engine 3
EIU 2
EIU 1
Ch A
Ch B
Pilot
MFD 2
Engine 4
Ch A
Center
MFD 5
Ch B
Copilot
MFD 3
Test Objectives
•
Verify the functionality of the EIDS
– Dual redundancy channels
– Display of Engine Parameters
• Torque
• Revolutions per minute
• Turbine Inlet Temperature
• Fuel Flow
• Engine Oil Temperature
• Engine Oil Pressure
• Gearbox Oil Pressure
• Oil Quantity
• Oil Cooler Flap Position
Test Setup
(LH Overhead Rack)
Eng #1 & #3
Sensors
EIU Adaptor
Cable #1
Analogue Gauges
(2 X 8)
EIU #1 (FS245)
Eng #2 & #4
Sensors
(LH Overhead Rack)
EIU Adaptor
Cable #2
EIU #2 (FS245)
Test Setup
Configuration 1
BOB_P1
BOB_P3
Breakout Box (FS245)
4
3
2 1
(LH Overhead Rack)
Eng #1 & #3
Sensors
Analogue Gauges
(2 X 8)
(Above MIP)
EIU Adaptor
Cable #1
Analogue
#1
#4
Eng #2 & #4
Sensors
(LH Overhead Rack)
EIU Adaptor
Cable #2
EIU #1 (FS245)
4
3
2 1
Digital
#2
BOB_P2
Ground_P1
EIU #2 (FS245)
BOB_P4
Ground_P2
#3
Test Setup
BOB_P1
Configuration 2
BOB_P3
Breakout Box (FS245)
4
3
2 1
(LH Overhead Rack)
Eng #1 & #3
Sensors
Analogue Gauges
(2 X 8)
(Above MIP)
EIU Adaptor
Cable #1
Analogue
#2
#3
Eng #2 & #4
Sensors
(LH Overhead Rack)
EIU Adaptor
Cable #2
4
3
2 1
EIU #1 (FS245)
Digital
SWAP
#1
BOB_P2
Ground_P1
EIU #2 (FS245)
BOB_P4
SWAP
Ground_P2
#4
Test Setup
TORQ
RPM
TIT
FF
OIL TEMP
OIL PRES
OIL QTY
OIL FLAPS
Engine(1,2)
Engine(4,3)
• 2 sets of 8 analog gauges were
arranged in 2 rows and mounted above
the Main Instrument Panel
Test Methodology
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Engine Operational Checkout
–
Conduct i.a.w Engine Ground Run Checklist with Analog gauges only
(Run 2 engines at a time)
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Pre Engine Run Check
Engine Start Up
Engine Run Up
Engine Performance Check (i.a.w TO 1C-130)
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•
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Feathering Check
Engine Shutdown and NTS Check
Post Engine Ground Run Check
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Low Speed Ground Idle (LSGI)
Ground Idle
Maximum Reverse
Flight Idle
Maximum Continuous
Take Off
Digital EIDS Checkout
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Repeat Test setup with Analog and EI DS (Run all 4 engines)
A – Analog; D - Digital
Test Methodology
Engine No/
Instrumentation
Run
Data collection
1
2
3
4
#1
A
-
-
A
Operational Checkout of engines integrity with 2 engines running
#2
-
A
A
-
Operational Checkout of engines integrity with 2 engines running
D
With all 4 engines running
Analog data collected to verify engines are operational.
Digital data (#1 & #4) collected to verify they fall within operational
criteria with similar indicating behavior as analog indicator.
A
Digital data collected to verify they fall within operational criteria with
similar indicating behavior as analog indicator.
Analog data collected to verify engines are operational.
#3
#4
D
A
A
D
A
D
Shut down engines & disconnect test setup.
Torque Calibration carried out: Minimum torque value required for the calibration
#5
D
D
D
D
Verified against criteria in engine checkout procedures
Conduct of Test
• Engine run was conducted with air crew
• Comparison was made between the analogue
gauge and digital display
• Observations were logged down for
improvement
23
Summary of improvements
Torque (TQ)
18538
18550
10851
10855
• Enlarged font for 10,000th & 1,000th digits
• Resolution of 50 in-lb instead of 1 in-lb
Fuel Flow (FF)
• Resolution of 5pph instead of 1pph
Engine Oil Quantity (EOQ)
• Resolution of 0.1 gallon instead of 1 gallon
10.0
10
Revolutions Per Minute (RPM)
• Enlarged font for 100th, 10th & 1th digits
• Resolution of 0.1% instead of 1%
• RPM indication at start up (Explained in the next few slides)
98
98.5
Lag in RPM indication
• It was observed that there is a significant lag in
the digital RPM indication upon engine start.
• This was found to be due to a RPM data
averaging algorithm in the EIU.
– The averaging algorithm has a 15 slot0buffer to
maintain the stability of the RPM data being
displayed
– At start up, the empty 15 slot buffers need to be
completely filled (about 5 – 6secs) before it sends
the first RPM data to the display.
EIU
Data 15
Data 14
Data 13
Data 12
Data 11
Data 10
Data 9
Data 8
Data 7
Data 6
Data 5
Data 4
Data 3
Data 2
Data 1
1st RPM
data to EID
RPM Indication Lag Operational Assessment
• There is NO operational implication due to RPM indication lag
– Ground Start : Flight Manual states that propeller rotation must occur within
5 secs of engaging the starter switch. – SATI S; Ground scanner confirmed
NTS light
propeller rotation occur at < 5 secs upon engaging engine start.
– Air Start : During flight, NTS light must
come on before 10% RPM is reached. Air
crew confirmed successful demonstration
of Air Start. – SATI S
RPM indication
100
Despite having no operational impact,
the EIU software was modified to
remove the lag in the RPM indication
at engine start up.
80
60
10.0
0
40
20
Improvement to RPM indication
At start up, any intermediate values in the buffer will be
im m ediately sent to EI D instead of waiting for the 15
EIU
slot buffer to be completely filled.
• RPM indication is shown almost
immediately when engine start
is engage
Data 15
0
Data 14
Data 13
Data 12
Data 11
Data 10
Data 9
Data 8
Data 7
Data 6
Data 5
Data 4
Data 3
Data 2
Data 1
1st RPM
data to EID
Key Success Factors
ST Aerospace’s successful prototype aircraft testing of the
C-130 was attributed to the following factors:
• Objective driven Test Team
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Rigorous review of test schemes by various stakeholders
Innovative Test Setup
Team of experienced engine runners and test crew
Close liaison with customer and key system suppliers
ST Aerospace is most willing to share our experience
on the C-130 modernization with you.
Please visit us at Booth 35
or contact us through email:
[email protected]
[email protected]
[email protected]
Thank You
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