Robot-Assisted Control Unit Testing for Complex Configurations

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Solution Overview

Problem

Testing control units in complex systems, such as aircraft cockpits, is time-consuming due to the need for numerous manual setting operations to check all configurations and functions, requiring a more efficient testing method.

Innovation Solution

A test system comprising a management server that provides predefined test instructions, a monitoring system that converts these instructions into operating instructions using assignment logic, and execution entities, such as robot arms, to set and verify test configurations on control units, with a system interface to capture and compare system states.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual setting operations are used to test control unit configurations, then testing can be performed with simple equipment, but the testing process becomes very time-consuming

Engineering Contradiction:

Improvetesting speedVSAvoidtest system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The test system automatically performs configuration setting and testing without human intervention. The control unit itself is configured by the testing system through automated control signals, eliminating the need for manual engineer operations and significantly reducing testing time while maintaining comprehensive test coverage

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical operations by engineers are replaced with an automated electronic control system. The testing system uses electronic control signals to configure the control unit and automate the testing process, substituting human manual operations with automated electronic mechanisms to improve testing efficiency

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Loss of time

If engineers manually set configurations for testing, then the test system remains simple, but numerous setting operations are required making the process time-consuming

Engineering Contradiction:

Improvetesting durationVSAvoidoperation simplicity

Core Design Contradiction:

Loss of timeVSEase of operation

Solution Approach 1:

The testing system pre-configures all necessary test parameters and control unit settings before actual testing begins. Test scenarios, configuration sequences, and expected outcomes are prepared in advance, allowing the automated system to execute comprehensive tests without requiring manual setup during the testing process itself

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

An automated control system acts as an intermediary between the tester and the control unit. This intermediary automatically manages all configuration settings and test executions, eliminating the need for engineers to perform numerous manual setting operations while ensuring accurate and consistent test procedures

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11442441B2Test system and robot arrangement for carrying out a test

Publication Date: 2022.09.13 AIRBUS DEFENCE & SPACE GMBH

AI summary

A test system is includes a management server which is configured to provide predefined test instructions, a monitoring system, and at least one execution entity. The monitoring system is configured to convert test instructions provided by the management server into operating instructions for setting a test configuration on a control unit of a system using predefined assignment logic. The at least one execution entity is configured to set the test configuration on the control unit of the system on the basis of operating instructions transmitted by the monitoring system to the at least one execution entity.