A method for automatically adapting iron bird test cables to aircraft design changes

Abstract

The present invention discloses a method for automatically adapting an iron bird test cable to aircraft design changes, comprising the following steps: S1, obtaining new electrical interface data and preprocessing, completing electrical interface data formatting, checking data integrity, removing data redundancy, and processing in a one-way manner from end to end; S2, identifying addition, deletion, and change signals in the electrical interface data, and generating principle change data; S3, adjusting the design changes of the interconnection principle of the electrical circuits of the test bench and the test piece, and generating line change data; S4, adjusting the wiring harness design changes, completing the addition of wiring harnesses, the insertion and removal of wires in the wiring harness, the deletion of wiring harnesses, the calculation of wiring harness length, diameter, and weight, and generating wiring harness change data; S5, adjusting wiring harness laying changes, completing changes in the wiring harness installation points, supports, fixtures, and wiring harness paths, and generating laying change data. The present invention can improve the efficiency and quality of the iron bird test cable in responding to frequent changes in aircraft design.

Description

Technical Field

[0001] The invention relates to the field of aircraft development, and in particular to a method for an iron bird test cable to automatically adapt to aircraft design changes. Background Art

[0002] With the rapid development of aircraft fly-by-wire flight control systems and avionics systems, the complexity and requirements of aircraft cables are becoming increasingly higher. The status of ground test platforms in aircraft development is becoming increasingly important. The most important of these is the iron bird test bench. In addition to completing the system-level integration verification of flight control, hydraulic and landing gear systems, it will also complete the aircraft-level integration verification of flight control, hydraulic, landing gear, avionics and power systems. As a result, the test cables of the iron bird are also more complex than traditional iron birds.

[0003] Iron bird testing must begin before aircraft final assembly, with the majority of R&D testing completed before the first flight. To ensure the progress of iron bird testing, the construction of the iron bird platform must be carried out in advance. During this period, the design, manufacture, and installation of the iron bird test cables must also be completed simultaneously. During this period, the aircraft design is not yet frozen and is in constant flux. The design of the iron bird test cables must also be constantly updated to adapt to the impact of these changes on the iron bird testing. The traditional design approach is to first draw a schematic, then a circuit diagram, then a wiring harness diagram, and finally a cable layout diagram.

[0004] Currently, the method to respond to an aircraft design change is to manually modify the schematic diagram, circuit diagram, wiring harness diagram and layout diagram. If the scope and number of changes are limited, the progress and quality can be guaranteed. However, due to the frequent aircraft design changes during the iron bird construction, the scope and number of circuit design changes are large, and the number of changes is also large. The manual modification method requires a lot of manpower and material resources, spends a lot of time and cost, and inevitably leads to more design errors, making it difficult to guarantee the quality and progress of cable design. In the later stage, there is a high incidence of incidents where cable quality problems affect the test. Summary of the Invention

[0005] An embodiment of the present invention proposes a method for an iron bird test cable to automatically adapt to aircraft design changes, which can solve the problem of high manpower, material and time costs in the process of iron bird test cables adapting to aircraft design changes. At the same time, it can also solve the problems of high cable failure rate and frequent design and manufacturing rework in later iron bird tests.

[0006] The embodiment of the present invention provides a method for automatically adapting an iron bird test cable to aircraft design changes, comprising the following steps:

[0007] S1. Obtaining an electrical interface data relationship table of a newly designed cable, performing redundancy processing on the data in the electrical interface data relationship table of the newly designed cable to obtain a processed electrical interface data relationship table;

[0008] S2. Compare the processed electrical interface data relationship table with the stored electrical interface data relationship table of the old cable design, identify the addition, deletion, and change signals in the processed electrical interface data relationship table, and generate principle change data;

[0009] S3. Generate a new route database based on the principle change data and the stored route database of the old design;

[0010] S4. Based on the new wiring route database, complete the addition of wiring harnesses, adjustment of wires in the wiring harnesses, and deletion of wiring harnesses to generate a new wiring harness database;

[0011] S5. Generate a new wiring database based on the new wiring harness database.

[0012] Optionally, the electrical interface data relationship table of the cable includes multiple connection relationships, each connection relationship including:

[0013] Cable serial number, slave end chapter number, slave end name, slave end mounting section, slave end mounting position, slave end abbreviation, slave end connector code, slave end pinhole number, slave end signal name, slave end pinhole definition version, slave end pinhole specifications, slave end interface release status, input / output, rated current, wire type, isolation code, destination end name, destination end mounting section, destination end mounting position, destination end abbreviation, destination end connector code, destination end pinhole number, destination end signal name, destination end pinhole definition version, destination end pinhole specifications, destination end interface release status, and signal type.

[0014] Optionally, performing redundancy removal on the data in the electrical interface data relationship table of the newly designed cable includes:

[0015] In the electrical interface data relationship table of the cable, one connection relationship is retained among repeated connection relationships, and one of the two connection relationships with opposite from-end information and to-end information is deleted.

[0016] Optionally, identifying added, deleted, and modified signals in the processed electrical interface data relationship table, including:

[0017] Determine the added and deleted signals in the processed electrical interface data relationship table and the stored electrical interface data relationship table of the old cable design according to the slave-end signal name and the destination-end signal name;

[0018] Determine the changed signal based on the stored electrical interface data relationship table of the old-design cable, the newly added and deleted signals, and the unchanged signals;

[0019] The unchanged signal is determined based on whether the from-end information, to-end information, isolation code, wire type, and signal type of the two connection relationships in the processed electrical interface data relationship table and the stored electrical interface data relationship table of the old designed cable are consistent.

[0020] Optionally, determining the newly added signal in the processed electrical interface data relationship table and the stored electrical interface data relationship table of the old-design cable according to the slave-end signal name and the destination-end signal name includes:

[0021] When neither the from-end nor the to-end in the processed electrical interface data relationship table can be found in the from-end and to-end in the stored electrical interface data relationship table of the old cable design, and the from-end signal name and to-end signal name in the processed electrical interface data relationship table can be found in the specific record set;

[0022] The specific record set is a set of records having the same from-end abbreviation and to-end abbreviation in the processed electrical interface data relationship table and the stored electrical interface data relationship table of the old-design cable, or vice versa.

[0023] Optionally, when the from-end information, to-end information, isolation code, wire type, and signal type of the two connection relationships in the processed electrical interface data relationship table and the stored electrical interface data relationship table of the old design cable are completely consistent, the connection relationship in the processed electrical interface data relationship table is determined to be an unchanged signal;

[0024] When the isolation codes, wire types, and signal types of two connection relationships from the processed electrical interface data relationship table and the stored electrical interface data relationship table of the old design cable are completely consistent, and the from-end information and to-end information are opposite to each other, the connection relationship in the processed electrical interface data relationship table is determined to be an unchanged signal.

[0025] Optionally, based on the new wiring route database, complete the addition of new wiring harnesses, adjustment of wires in the wiring harnesses, and deletion of wiring harnesses to generate a new wiring harness database, including:

[0026] Determine the wires included in the changed wiring harness, deleted wiring harnesses, and newly added wiring harnesses based on the isolation codes in the new wiring route database;

[0027] Based on the changes to the wires included in the harness, the deletion of harnesses, and the addition of new harnesses, the harness length, diameter, and mass are calculated to generate a new harness database.

[0028] Optionally, calculate the length, diameter, and mass of the harness, including:

[0029] Calculate the harness diameter based on the wires included in the changed harness, deleted harnesses, and newly added harnesses;

[0030] Determine the harness nodes based on the harness diameter;

[0031] Determine the harness length based on the harness node;

[0032] Determine the quality of the harness based on its length.

[0033] Optionally, the harness length is calculated as follows:

[0034]

[0035] The length of the harness is l, there are n nodes on the harness, and the coordinates of the i-th node are (x i ,y i ,z i ); The nodes of the harness include the test piece installation point, the test system installation point, the support installation point, the clamp installation point, the binding point and the separation surface installation point.

[0036] The present invention provides a method for automatically adapting an iron bird test cable to aircraft design changes, which has the following beneficial effects: it can solve the problem of high manpower, physical force, and time costs in the process of adapting the iron bird test cable to frequent aircraft design changes, and can also solve the problems of high cable failure rate and frequent design and manufacturing rework in later iron bird tests. Through data import and preprocessing in step S1, the data volume of the automatic adaptation algorithm is minimized, the calculation amount is reduced, and the data processing efficiency is improved. At the same time, the integrity check ensures the integrity of the electrical interface data. In step S2, a comparison algorithm based on signal name is added between the slave end and the target end on the basis of general data comparison, which has strong fault tolerance and enhances the accuracy of identifying new and deleted signals, greatly reducing the false recognition rate, avoiding the addition of a large number of wires due to false recognition, and thus saving costs. In step S3, the wiring relationship between the test cable and the test system is modified and adjusted to ensure that the cross-linking requirements of the iron bird test are correctly met, avoiding potential errors. Through the automatic adjustment method of the wiring harness design and routing elements and related drawings in steps S4 and S5, the efficiency and accuracy of the wiring harness design are improved, and errors and inefficiencies introduced by human factors are avoided. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Figure 1 It is a flow chart of the method for automatically adapting the iron bird test cable to design changes provided by the present invention. DETAILED DESCRIPTION

[0038] The following is a clear and complete description of the technical solutions in the embodiments of the present invention, in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts are within the scope of protection of the present invention.

[0039] The present invention provides a method for an iron bird test cable to automatically adapt to aircraft design changes. Figure 1 As shown in , the following steps are included:

[0040] S1. Obtain electrical interface data and preprocess the cables with design changes.

[0041] The electrical interface data of the cable whose design is changed is the electrical interface data of the new cable. For example, a relation table of the new and old versions of the electrical interface data can be established based on a MySQL database (not limited to a MySQL database).

[0042] Among them, the data structures in the electrical interface data relationship table of the new and old versions include: serial number (unique serial number), chapter number to which the slave end belongs, slave end name, slave end installation section, slave end installation position, slave end abbreviation, slave end connector code, slave end pinhole number, slave end signal name, slave end pinhole definition version, slave end pinhole specification, slave end interface release status, input / output, rated current, wire type, isolation code, end end name, end end installation section, end end installation position, end end abbreviation, end end connector code, end end pinhole number, end end signal name, end end pinhole definition version, end end pinhole specification, end end interface release status, and signal type.

[0043] The section number represents the system number of the ATA (Air Transport Association) specification; the interface release status represents whether the interface is released or unreleased; the abbreviation represents the abbreviation of the device; the isolation code indicates which type of isolation specification the wire should comply with; the from-end device, and the to-end device.

[0044] At the same time, if the new version of the electrical interface data relationship table provided this time is the first design version, a line path database must be established. The data structure must at least include: starting point (generally from the end device connector, that is, from the end pinhole or terminal) → intermediate path node (one or more separation surfaces) → end point (to the pinhole or terminal at the end connector). A wiring harness and routing database must be established. The data structure must at least include: starting point (from the pinhole or terminal of the end connector) → intermediate path node (one or more, which may be clamps, supports, and binding points) → end point (to the pinhole or separation surface module or terminal at the end connector).

[0045] The line route database corresponds to the various design elements of the iron bird test cable line diagram, and the harness database corresponds to the iron bird test cable harness and laying design elements.

[0046] Correspondingly, for the old version of the electrical interface data relationship table, the line route database and wiring harness and laying database corresponding to the version are determined to facilitate design modifications based on this.

[0047] After obtaining a new electrical interface database, a computer program can be used to format (store in a preset format) and check data integrity according to the data structure of the electrical interface data relationship table (the data structure described in S1 is the header format of the relationship table), and then remove redundant data, that is, remove duplicate connection relationships, and only retain one connection relationship in which "input / output" is output. The connection relationship is a data record stored in the data table. The redundant data includes one of the following situations:

[0048] A) Duplicate records;

[0049] B) The slave information of a certain record (set as record 1) is the same as the destination information of another record (set as record 2), and the destination information of record 1 is the same as the slave information of record 2.

[0050] For example, it is understood that when incomplete data is detected, a log may be generated and fed back to the responsible designer.

[0051] S2. Identify the added, deleted, and changed signals in the electrical interface data and generate principle change data.

[0052] The principle change data refers to the change of the connection relationship from the end device to the end device.

[0053] Exemplarily, the database is accessed through application software, and the new version of the electrical interface data is compared with the old version of the data in the database for identification.

[0054] The logic for identifying newly added signals is as follows: the slave end in the new wiring relationship cannot find a record in either the slave end or the to end in the old version of the data, and the to end cannot find a record in either the slave end or the to end in the old version of the data, and the following conditions cannot be found in a specific record set:

[0055] a) The slave signal name is consistent with the slave signal name and / or destination signal name in the specific record set;

[0056] b) The destination signal name is consistent with the slave signal name and / or destination signal name in the specific record set.

[0057] Suppose record sets A1 and A2 are as follows:

[0058] A1={the combination of (from end abbreviation, to end abbreviation) in the new version data is the same as the combination of (from end abbreviation, to end abbreviation) in the old version data};

[0059] A2={the combination of (from-end abbreviation, to-end abbreviation) and (to-end abbreviation, from-end abbreviation) in the new version data is the same}.

[0060] Then the specific record set mentioned in a) and b) refers to: A1∪A2.

[0061] The deletion signal is identified by comparing the old version data with the new version data, using the same algorithm as that for identifying the new addition signal, thereby identifying the deletion signal.

[0062] The identification change signal is the following algorithm logic:

[0063] Assume that the set of change signals is Sc, the set of unchanged signals is Sn, the set of deletion signals is Sd, and the full set of old data is Qy. Then the identified set of change signals is as follows:

[0064] Sc=Qy-Sn–Sd

[0065] The unchanged signal set Sn is composed of records that meet one of the following conditions:

[0066] a) The slave information of a record (set as Siy1) in the old version of the data is consistent with the slave information of a record (set as Six1) in the new version of the data, and the destination information of Siy1 is consistent with the destination information of Six1, and the isolation code, wire type, and signal type of Siy1 and Six1 are consistent;

[0067] b) The slave information of a record (set as Siy2) in the old version of the data is consistent with the destination information of a record (set as Six2) in the new version of the data, and the destination information of Siy2 is consistent with the slave information of Six2, and the isolation code, wire type and signal type of Siy2 and Six2 are consistent.

[0068] Finally, based on the identified addition, deletion and change signals, the old version of the data is updated as the current valid data, and change records with change time and change content are generated for these principle changes and stored in the database for recording changes and rolling back data.

[0069] S3. Adjust the design changes of the electrical circuit interconnection principle of the test bench and test piece, and generate circuit change data.

[0070] According to the principle change data generated in step S2 and in combination with the test requirements, the wiring relationship of the bus wiring system, data acquisition system, exciter system and tester system is adjusted according to the change of signal type to ensure that the cross-linking requirements of the iron bird test are correctly implemented.

[0071] The signal type change will alter the wiring channel allocation and the pinhole assignment of the wiring system connectors. Other system adjustments are made based on the test function. After these adjustments, the circuit change data is generated and the iron bird test cable circuit diagram is automatically updated.

[0072] S4. Adjust the harness design changes, complete the addition of new harnesses, adjustment of wires in the harness, and deletion of harnesses, recalculate the harness length, diameter, and mass, and generate harness change data.

[0073] Change the wires included in the harness according to the isolation code. Assume that the maximum number of wires in the harness is MAX, for example, MAX = 100 (not limited to 100). Possible situations:

[0074] 1) Add wiring harness

[0075] A new isolation code is added or the new isolation code after the change cannot find a wiring harness with an excess number of conductors;

[0076] 2) Change the wiring harness including the wires

[0077] If the wire isolation code is changed to an existing isolation code and the wires can be found without exceeding the maximum number of wires in the custom harness, the changed wires need to be deleted from the original harness, added to the new harness, and the harness diameter recalculated. The clamps, supports, and surge protectors should be selected based on the diameter. The specific steps are as follows:

[0078] a) Identify the wiring harness involved in the wiring change;

[0079] b) Mark each wire harness that needs to be adjusted;

[0080] c) Find the incoming wiring harness and mark it.

[0081] 3) Delete the harness

[0082] The number of wires in a harness has been deleted and the harness should be deleted from the database.

[0083] The calculation of the harness length is based on the spatial coordinates of the updated harness nodes. The harness nodes include the test piece installation point, the test system installation point, the support installation point, the clamp installation point, the lashing point, and the separation surface installation point. Assume that the harness length is l, there are n nodes on the harness, and the coordinates of the i-th node are (x i ,y i ,zi ), the harness length is calculated as follows:

[0084]

[0085] Based on the diameter of the wires in the harness, the cable diameter can be calculated in aggregate, resulting in the diameter change of the harness jacket, where i is an integer from 2 to n.

[0086] Assume the total mass of the harness is M, the length of the harness is l, and the mass per unit length of the jth wire is m j , k is the total number of wires, then the harness quality is calculated as follows:

[0087]

[0088] Wherein, j is an integer from 1 to k.

[0089] S5. Adjust the wiring harness routing changes, complete the changes to the wiring harness installation points, supports, fixtures, and wiring harness paths, and generate routing change data.

[0090] In step S5, the position coordinates of the harness installation points, supports, and fixtures in the three-dimensional diagram are changed, the background database is modified, and the three-dimensional harness layout diagram is automatically changed through the software, thereby realizing automated changes to the harness layout diagram.

[0091] The above is a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principles of the present invention. These improvements and modifications are also considered to be within the scope of protection of the present invention.

Claims

1. A method for automatically adapting an iron bird test cable to aircraft design changes, characterized in that: The steps include: S1. Obtaining an electrical interface data relationship table of a newly designed cable, performing redundancy processing on the data in the electrical interface data relationship table of the newly designed cable to obtain a processed electrical interface data relationship table; S2. Compare the processed electrical interface data relationship table with the stored electrical interface data relationship table of the old cable design, identify the addition, deletion, and change signals in the processed electrical interface data relationship table, and generate principle change data; S3. Generate a new route database based on the principle change data and the stored route database of the old design; S4. Based on the new wiring route database, complete the addition of wiring harnesses, adjustment of wires in the wiring harnesses, and deletion of wiring harnesses to generate a new wiring harness database; S5. Generate a new wiring database based on the new wiring harness database; Identify added, deleted, and modified signals in the processed electrical interface data relationship table, including: Determine, based on the slave-end signal name and the destination-end signal name of the connection relationship in the processed electrical interface data relationship table, whether to add or delete signals in the processed electrical interface data relationship table and the stored electrical interface data relationship table of the old cable design; Determine the changed signal based on the stored electrical interface data relationship table of the old-design cable, the newly added and deleted signals, and the unchanged signals; The unchanged signal is determined based on whether the slave end information, destination end information, isolation code, wire type and signal type of the two connection relationships in the processed electrical interface data relationship table and the stored electrical interface data relationship table of the old design cable are consistent; The principle change data refers to the change of the connection relationship from the end device to the end device.

2. The method according to claim 1, characterized in that The cable's electrical interface data relationship table includes multiple connection relationships, each of which includes: The serial number of the connection relationship, the chapter number to which the slave end belongs, the slave end name, the slave end mounting section, the slave end mounting position, the slave end abbreviation, the slave end connector code, the slave end pinhole number, the slave end signal name, the slave end pinhole definition version, the slave end pinhole specification, the slave end interface release status, input / output, rated current, wire type, isolation code, end end name, end end mounting section, end end mounting position, end end abbreviation, end end connector code, end end pinhole number, end end signal name, end end pinhole definition version, end end pinhole specification, end end interface release status, and signal type.

3. The method according to claim 2, characterized in that The de-redundancy processing of the data in the electrical interface data relationship table of the newly designed cable includes: In the electrical interface data relationship table of the cable, one connection relationship is retained among repeated connection relationships, and one of the two connection relationships with opposite from-end information and to-end information is deleted.

4. The method according to claim 1, wherein The step of determining the newly added signal in the processed electrical interface data relationship table and the stored electrical interface data relationship table of the old-design cable according to the slave-end signal name and the destination-end signal name includes: When neither the from-end nor the to-end in the processed electrical interface data relationship table can be found in the from-end and to-end in the stored electrical interface data relationship table of the old cable design, and the from-end signal name and to-end signal name in the processed electrical interface data relationship table can be found in the specific record set; The specific record set is a set of records having the same from-end abbreviation and to-end abbreviation in the processed electrical interface data relationship table and the stored electrical interface data relationship table of the old-design cable, or vice versa.

5. The method according to claim 1, wherein When the from-end information, to-end information, isolation code, wire type, and signal type of the two connection relationships in the processed electrical interface data relationship table and the stored electrical interface data relationship table of the old design cable are completely consistent, the connection relationship in the processed electrical interface data relationship table is determined to be an unchanged signal; When the isolation codes, wire types, and signal types of two connection relationships from the processed electrical interface data relationship table and the stored electrical interface data relationship table of the old design cable are completely consistent, and the from-end information and to-end information are opposite to each other, the connection relationship in the processed electrical interface data relationship table is determined to be an unchanged signal.

6. The method according to claim 1, characterized in that Based on the new wiring database, complete the addition of new wiring harnesses, adjustment of wires in the wiring harnesses, and deletion of wiring harnesses to generate a new wiring harness database, including: Determine the wires included in the changed wiring harness, deleted wiring harnesses, and newly added wiring harnesses based on the isolation codes in the new wiring route database; Based on the changes to the wires included in the harness, the deletion of harnesses, and the addition of new harnesses, the harness length, diameter, and mass are calculated to generate a new harness database.

7. The method according to claim 6, characterized in that Calculates harness length, diameter, and mass, including: Calculate the harness diameter based on the wires included in the changed harness, deleted harnesses, and newly added harnesses; Determine the harness nodes based on the harness diameter; Determine the harness length based on the harness node; Determine the quality of the harness based on its length.

8. The method according to claim 7, characterized in that The harness length is calculated using the following formula: ； Among them, the length of the harness is l, there are n nodes on the harness, and the coordinates of the i-th node are ; The nodes of the wiring harness include the test piece installation point, the test system installation point, the support installation point, the clamp installation point, the binding point and the separation surface installation point.

Images