Side stick sensor test bench

Abstract

This application provides a side rod sensor test bench, including: a chassis, a front panel, a power input interface, multiple device-under-test (DUT) connectors, multiple data acquisition interfaces, and a measurement circuit. The front panel is located at the front of the chassis, and the power input interface is located on the front panel for connecting an external DC power supply. The DUT connectors are used to connect the side rod sensor assembly, and the data acquisition interfaces are used to connect to a data acquisition platform. The measurement circuit is located inside the chassis and includes multiple measurement channels. Each measurement channel is connected to a potentiometer under test. The measurement channels are based on the series voltage divider principle, and the voltage signal is acquired by the data acquisition platform to calculate the resistance value of the potentiometer under test. Through reasonable structural design and circuit configuration, this application achieves accurate measurement of the potentiometer resistance value of the side rod sensor assembly, with high testing accuracy, low cost, and simple operation, fully meeting the testing requirements of the CMM manual.

Description

Technical Field

[0001] This utility model relates to the field of aviation maintenance and testing equipment technology, and in particular to a brush fault detection test bench for side rod sensor assemblies. Background Technology

[0002] The side stick sensor assembly (PNR: 321000 series) converts mechanical motion into electrical signals in the flight control system. During maintenance, brush fault detection is required. According to CMM27-92-13, a dedicated test bench is needed to measure the dynamic resistance of the potentiometers within the assembly. The original manufacturer's test bench (T11) is expensive; therefore, a self-made test bench with equivalent testing capabilities needs to be developed.

[0003] Currently, brush fault detection in the operational testing of the side rod sensor assembly requires the T11 test bench specified in the manual to dynamically measure the resistance of the potentiometers within the assembly. Existing testing methods suffer from high equipment costs and difficulty in guaranteeing testing accuracy. Utility Model Content

[0004] In view of the problems existing in the prior art, the purpose of this utility model is to provide a side rod sensor test bench with reasonable structure, high testing accuracy and low cost, which can completely replace the original test bench required for this test in the CMM manual.

[0005] This utility model provides a side rod sensor test bench, including a chassis, a panel, a power input interface, multiple device-under-test (DUT) connectors, multiple data acquisition interfaces, and a measurement circuit. The panel is located at the front of the chassis, and the power input interface is located on the panel for connecting an external DC power supply. The DUT connectors are used to connect side rod sensor assemblies, and the data acquisition interfaces are used to connect to a data acquisition platform. The measurement circuit is located inside the chassis and includes multiple measurement channels. Each measurement channel is connected to a potentiometer under test. The measurement channels are based on the series voltage divider principle, and the voltage signal is acquired by the data acquisition platform to calculate the resistance value of the potentiometer under test.

[0006] Both the device under test connector and the data acquisition interface are multi-pin connectors, and the power input interface includes at least one pair of banana plugs.

[0007] The number of measurement channels is twelve, each corresponding to one of the twelve potentiometers in the side rod sensor assembly.

[0008] The data acquisition platform includes multiple voltage acquisition channels, which include multiple low-voltage acquisition channels and multiple high-voltage acquisition channels.

[0009] The side rod sensor test bench also includes a crank-rocker mechanism connected to the side rod sensor assembly, which drives the side rod sensor assembly to reciprocate about an axis at a speed of less than one degree per minute.

[0010] The rotation range of the crank rocker mechanism is between one and two degrees to the left and right of the center position of the side rod sensor assembly.

[0011] Each measurement channel in the measurement circuit includes a fixed-value resistor connected in series with the potentiometer under test. The data acquisition platform is used to acquire the voltage value across the fixed-value resistor. The fixed-value resistor is one megaohm.

[0012] The side rod sensor test bench also includes multiple dedicated connecting cables, which are equipped with anti-misinsertion structures and are used to connect the side rod sensor assembly, the test bench, and the data acquisition platform.

[0013] The data acquisition platform is used to plot the voltage change curve over time in real time and to calculate the resistance change curve over time.

[0014] This invention, through reasonable structural design and circuit configuration, achieves accurate measurement of the potentiometer resistance value of the side rod sensor assembly. It boasts high testing accuracy, low cost, and simple operation, fully meeting the testing requirements of the CMM manual. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the overall connection structure of the side rod sensor test bench of this utility model; Figure 2 This is a schematic diagram of the test bench panel layout of this utility model; Figure 3 This is a schematic diagram of the potentiometer channel of this utility model; Figure 4 This is a schematic diagram of the data acquisition platform interface of this utility model; Figure 5 This is a schematic diagram of the crank-connecting rod mechanism of this utility model; Figure 6 This is a schematic diagram of the measurement circuit of this utility model.

[0016] Reference numerals in the attached drawings: side rod sensor test bench 100, chassis 101, power input interface 103, device under test connector 104, data acquisition interface 105, data acquisition platform 110, dedicated connection cable 111. Detailed Implementation

[0017] The present application will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the relevant utility model and are not intended to limit the scope of the utility model.

[0018] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other.

[0019] The present application will now be described in detail with reference to the accompanying drawings and embodiments.

[0020] Please refer to Figure 1 , Figure 2 , Figure 3 , Figure 4 This document illustrates a first embodiment of a side rod sensor test bench according to the present invention. The side rod sensor test bench includes: a chassis, a front panel, a power input interface, multiple device-under-test (DUT) connectors, multiple data acquisition interfaces, and a measurement circuit. The front panel is located at the front of the chassis, and the power input interface is located on the front panel for connecting an external DC power supply. The DUT connectors are used to connect side rod sensor assemblies, and the data acquisition interfaces are used to connect to a data acquisition platform. The measurement circuit is located inside the chassis and includes multiple measurement channels. Each measurement channel is connected to a potentiometer under test. The measurement channels are based on the series voltage divider principle, and the voltage signal is acquired through the data acquisition platform to calculate the resistance value of the potentiometer under test.

[0021] like Figures 1 to 4 As shown, the side-mounted sensor test bench includes a chassis 101, a panel, a power input interface 103, multiple device-under-test (DUT) connectors 104, multiple data acquisition interfaces 105, and a measurement circuit. The panel is fixedly mounted on the front of the chassis 101, made of metal, and possesses good mechanical strength and electromagnetic shielding performance. The power input interface 103 is located on the left side of the panel and is used to connect to a 1VDC external DC power supply. Four DB26 multi-pin connectors 104 are evenly distributed in the middle of the panel. The data acquisition interfaces 105 also use DB26 multi-pin connectors and are located in positions corresponding to the DUT connectors 104. The measurement circuit is located inside the chassis 101 and is fixedly mounted via a circuit board. The measurement circuit includes twelve measurement channels, each connected to a potentiometer under test. The measurement channels are designed based on the series voltage divider principle, acquiring voltage signals through the data acquisition platform 110 and calculating the resistance value of the potentiometer under test. The data acquisition platform provided in this application is the 9927 data acquisition platform.

[0022] This embodiment provides the basic structural framework of the test bench, ensuring the reasonable layout and reliable connection of each functional module, laying the foundation for the subsequent implementation of test functions.

[0023] In some preferred embodiments, both the device under test connector and the data acquisition interface are multi-pin connectors, and the power input interface includes at least one pair of banana plugs.

[0024] Both the DUT connector 104 and the data acquisition interface 105 are DB26 multi-pin connectors, offering excellent connection reliability and signal transmission performance. The power input interface 103 includes a pair of banana-shaped jacks with a 4mm diameter, conforming to standard power interface specifications. The DUT connector 104 is directly connected to the measurement circuit via internal wiring, with each connector corresponding to three measurement channels. The data acquisition interface 105 is also connected to the measurement circuit via a shielded cable, ensuring stable signal transmission. The banana-shaped jacks are made of brass with a gold-plated finish, providing good conductivity and corrosion resistance.

[0025] This embodiment improves the transmission quality and connection reliability of test signals and reduces the impact of contact resistance on test accuracy by optimizing the connector structure and material selection.

[0026] In some preferred embodiments, the number of measurement channels is twelve, each corresponding to one of the twelve potentiometers in the side rod sensor assembly.

[0027] There are twelve measurement channels, each corresponding to one of the twelve potentiometers in the side rod sensor assembly. Each measurement channel operates independently without interference. The twelve measurement channels are divided into four groups of three channels each, led out through a single device-under-test connector 104. Each measurement channel includes signal conditioning circuitry, filtering circuitry, and protection circuitry to ensure the accuracy and stability of the test signal. The wiring of the measurement channels adopts a star topology to reduce crosstalk between channels.

[0028] This embodiment achieves parallel testing of multiple channels through reasonable channel configuration and cabling design, which improves testing efficiency and ensures the accuracy of test results for each channel.

[0029] In some preferred embodiments, the data acquisition platform includes multiple voltage acquisition channels, which include multiple low-voltage acquisition channels and multiple high-voltage acquisition channels.

[0030] The data acquisition platform 110 includes eight low-voltage acquisition channels and four high-voltage acquisition channels, totaling twelve voltage acquisition channels. The low-voltage acquisition channels have a range of ±1V and a resolution of 0.1mV, suitable for small signal acquisition. The high-voltage acquisition channels have a range of ±10V and a resolution of 1mV, suitable for larger signal acquisition. The data acquisition platform 110 uses a 24-bit ADC chip, featuring high precision and low noise. The data acquisition platform 110 connects to the test bench via a data acquisition interface 105, with each acquisition channel corresponding to one measurement channel. The data acquisition platform 110 has a built-in processor capable of processing the acquired data in real time and plotting voltage-time curves.

[0031] This embodiment optimizes the configuration of the data acquisition platform, achieving high-precision, multi-channel voltage signal acquisition, thus providing a reliable data foundation for subsequent resistance calculations.

[0032] In some preferred embodiments, the side rod sensor test bench further includes a crank-rocker mechanism connected to the side rod sensor assembly for driving the side rod sensor assembly to reciprocate about an axis at a speed of less than one degree per minute. The rotation range of the crank-rocker mechanism is between one and two degrees to the left and right of the center position of the side rod sensor assembly.

[0033] Please refer to Figure 5 The crank-rocker mechanism is connected to the side rod sensor assembly, driving the side rod sensor assembly to reciprocate around its axis at a speed of less than 1° / min. The crank-rocker mechanism includes a stepper motor, a reducer, a crank connecting rod, and a position sensor. The stepper motor reduces its speed to the required test speed via the reducer, and the crank connecting rod converts the rotational motion into reciprocating oscillation. The position sensor monitors the rotation angle in real time, ensuring the rotation range is between 1° and 2° to the left and right of the center position. The control system of the crank-rocker mechanism uses closed-loop control, enabling precise control of the rotation speed and angle range. During testing, the side rod sensor assembly reciprocates continuously for 4 hours under the drive of the crank-rocker mechanism.

[0034] This embodiment achieves precise motion control required for testing through a sophisticated mechanical structure and control system, providing standard test conditions for brush fault testing.

[0035] As required by CMM27-92-13 manual, the brush failure test requires the side rod sensor assembly to be rotated around the axis at a speed of less than 1° / MIN, and the measurement range can only be 1° to 2° to the left and right of the middle point, with a test duration of 4 hours.

[0036] In some preferred embodiments, each measurement channel in the measurement circuit includes a fixed-value resistor connected in series with the potentiometer under test. The data acquisition platform is used to acquire the voltage value across the fixed-value resistor. The fixed-value resistor is one megaohm.

[0037] Please refer to Figure 1 , Figure 6 Each measurement channel in the measurement circuit includes a fixed-value resistor with a resistance of 1MΩ and an accuracy of 0.1%. The fixed-value resistor is connected in series with the potentiometer under test, forming a voltage divider circuit. When a 1VDC power supply is input, the data acquisition platform 110 acquires the voltage value Um across the fixed-value resistor and calculates the resistance value of the potentiometer under test using the formula R=1 / Um-1, where R is in MΩ. The measurement circuit adopts a four-layer PCB design, with independent power and ground layers to reduce noise interference. Each measurement channel is equipped with overvoltage and overcurrent protection circuits to ensure test safety.

[0038] Since each of the 12 measurement channels of the required mobile data acquisition platform 9927 has a 1MΩ resistor connected in series, the resistors in the measurement circuit can be replaced by the internal resistors of the mobile data acquisition platform.

[0039] This embodiment achieves high-precision resistance measurement through optimized circuit design and component selection, with a measurement accuracy of four decimal places, fully meeting the test requirements of the manual.

[0040] Please refer to this again. Figure 6 The main function of this test bench is to perform brush failure testing on the side rod sensor assembly. This test requires using a crank-connecting rod mechanism to control the side rod sensor assembly to slowly move back and forth within a 2° radius of its center position. Simultaneously, the resistance change of the potentiometer inside the assembly is measured. The manual specifies that the resistance should not exceed 0.03MΩ (30KΩ). Therefore, it can be tested... Figure 6 The circuit shown measures and collects the value of Um, and then calculates the change in the resistance R of the component during the test using the conversion formula R=1 / Um-1.

[0041] Figure 6 The 1V power supply can be supplied by the company's existing DC power supply; each side rod sensor assembly has 12 potentiometers (some part numbers only have 10), so a total of 12 measurement channels are required to perform measurements simultaneously, and the power input of each channel is connected in parallel.

[0042] In some preferred embodiments, multiple dedicated connecting cables are also included, which are equipped with anti-misinsertion structures for connecting the side rod sensor assembly, the test bench, and the data acquisition platform.

[0043] The dedicated connection cable 111 features an anti-misconnection structure, including keyway positioning, color coding, and physical limits. The dedicated connection cable 111 includes four main cables: cable J1 connects the device under test (DUT) to the test bench, cable J2 connects the test bench to the data acquisition platform, and cables J3 and J4 are auxiliary test cables. Each cable's connector has a unique keyway position to prevent incorrect connection. The cables use shielded twisted-pair cable to reduce electromagnetic interference. The connector contacts are gold-plated to ensure good conductivity and corrosion resistance. The cable sheaths use different colors for easy identification and connection.

[0044] This embodiment ensures the accuracy and reliability of the test connection through anti-misinsertion design and high-quality material selection, reducing human error.

[0045] In some preferred embodiments, the data acquisition platform is used to plot the voltage change curve over time in real time and to calculate the resistance value change curve over time.

[0046] The data acquisition platform 110 is used to plot voltage changes over time in real time and calculate the resistance changes over time. The software system of the data acquisition platform 110 can display the voltage curves of twelve channels in real time while recording raw data. The software has a built-in algorithm that can automatically calculate the resistance value of each channel and plot the resistance-time curve. During the test, the software monitors the change in resistance value in real time and automatically alarms when the resistance value exceeds 0.03MΩ (30kΩ). After the test, the software generates a test report, including graphs, data tables, and test conclusions.

[0047] The data acquisition platform, the 9927 mobile data acquisition platform, is primarily used to meet the requirements for plotting curves during testing, including solenoid valve energization response curves, brake torque response curves, pressure release time curves, and displacement-velocity curves; it can also be used for long-term parameter monitoring. When acquiring the required measurement value Um, the company's 9927 mobile data acquisition platform can be used; the required 12 acquisition channels consist of 8 low-voltage acquisition channels and 4 high-voltage acquisition channels of the 9927 mobile data acquisition platform. The specific channel locations are as follows... Figure 4 As shown. Preliminary testing has verified that the above channels can perform data acquisition for this test.

[0048] This embodiment achieves automation and visualization of the testing process through improved data processing and display functions, greatly improving testing efficiency and result reliability.

[0049] This application also provides the following testing steps: 1. Connect the device under test connector 104 on the left side of the panel to the side rod sensor assembly using the dedicated connection cable 111, and connect the data acquisition interface 105 on the right side of the panel to the data acquisition platform 110. 2. Connect 1VDC voltage to the banana plug of the power input interface 103 on the test bench; 3. Turn on the 1VDC power control switch and input a 1V DC voltage; 4. Turn on the data acquisition platform 110 and connect the twelve channels to be tested to the acquisition channels of the data acquisition platform 110; 5. Open the data acquisition software, select the range of the corresponding channel as ±1V or ±1.5V, and perform data acquisition; 6. Start the crank rocker mechanism to make the side rod sensor assembly reciprocate within a range of 2° to the left and right of the center position at a speed of less than 1° / min; 7. Continuously test for 4 hours, monitoring the resistance value change in real time; 8. Export the collected data, calculate the potentiometer resistance value, and determine whether it meets the requirements of the manual.

[0050] It should be noted that, through actual testing and verification, the side rod sensor test stand of this utility model has the following effects: 1. High testing accuracy, with voltage measurement accuracy reaching 0.1mV and resistance calculation accuracy meeting manual requirements; 2. The test showed good stability, with no abnormalities observed after 4 hours of continuous operation; 3. Easy to operate, and the anti-misoperation design effectively prevents accidental operation; 4. Low cost, saving a significant amount of procurement costs compared to the original manufacturer's testing station; 5. Fully meets the testing requirements of CMM27-92-13 manual and can be used for repair certification of side rod sensor assemblies.

[0051] This invention is not only applicable to the 321000 series side rod sensor assembly, but can also be extended to the testing of other similar sensors, and has broad application prospects.

[0052] The above are merely some embodiments of this utility model. For those skilled in the art, various modifications and improvements can be made without departing from the inventive concept of this utility model, and these all fall within the protection scope of this utility model.

Claims

1. A side rod sensor test bench, characterized in that, include: Chassis, front panel, power input interface, multiple device under test connectors, multiple data acquisition interfaces, and measurement circuitry; The panel is located at the front of the chassis, and the power input interface is located on the panel for connecting an external DC power supply; The connector for the device under test is used to connect to the side rod sensor assembly, and the data acquisition interface is used to connect to the data acquisition platform. The measurement circuit is located inside the chassis and includes multiple measurement channels. Each measurement channel is connected to a potentiometer under test. The measurement channel is based on the series voltage divider principle and acquires voltage signals through the data acquisition platform to calculate the resistance value of the potentiometer under test.

2. The side rod sensor test bench according to claim 1, characterized in that, Both the device under test connector and the data acquisition interface are multi-pin connectors, and the power input interface includes at least one pair of banana plugs.

3. The side rod sensor test bench according to claim 1, characterized in that, The number of measurement channels is twelve, each corresponding to one of the twelve potentiometers in the side rod sensor assembly.

4. The side rod sensor test bench according to claim 1, characterized in that, The data acquisition platform includes multiple voltage acquisition channels, which include multiple low-voltage acquisition channels and multiple high-voltage acquisition channels.

5. The side rod sensor test bench according to claim 1, characterized in that, It also includes a crank-rocker mechanism connected to the side rod sensor assembly for driving the side rod sensor assembly to reciprocate about an axis at a speed of less than one degree per minute.

6. The side rod sensor test bench according to claim 5, characterized in that, The rotation range of the crank-rocker mechanism is between one and two degrees to the left and right of the center position of the side rod sensor assembly.

7. The side rod sensor test bench according to claim 1, characterized in that, Each measurement channel in the measurement circuit includes a fixed-value resistor, which is connected in series with the potentiometer under test. The data acquisition platform is used to acquire the voltage value across the fixed-value resistor.

8. The side rod sensor test bench according to claim 7, characterized in that, The fixed resistance value is one megaohm.

9. The side rod sensor test bench according to claim 1, characterized in that, It also includes multiple dedicated connecting cables, which are equipped with anti-misinsertion structures and are used to connect the side rod sensor assembly, the test bench, and the data acquisition platform.

10. The side rod sensor test bench according to claim 1, characterized in that, The data acquisition platform is used to plot the voltage change curve over time in real time and to calculate the resistance change curve over time.

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