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The PC-Based Counter Timer Test Rig (Panel 72S.7317 & Timer 72S.6527) is a fully automated, intelligent testing system designed to evaluate the functionality and reliability of aviation components, particularly the APD-99 Series 5 used in aircraft. Developed to meet the stringent requirements of Hindustan Aeronautics Limited (HAL), this test rig is a fusion of modern electronics, user-friendly software, and high-precision measurement tools. System Overview This test rig functions as a vital quality assurance tool for HAL. It simulates various operating conditions that an aviation component would encounter during flight and checks how the component responds to those conditions. The system includes: • A main control panel (Panel 72S.7317) with digital displays for voltage and current. • A 16-channel PC-based stopwatch timer (Timer 72S.6527) that can measure multiple events simultaneously with millisecond precision. • A rugged industrial computer and touchscreen interface. • Custom-developed software based on LabVIEW for automation and data logging. • Emergency stop systems and safety interlocks to protect the operator and equipment. This test rig is capable of working in manual, semi-automatic, and fully automatic modes, giving flexibility to engineers based on the complexity of testing. Detailed Technical Specifications Electrical & Power System: • DC Supply: 27V (typical aircraft component power requirement) • AC Supply: 220V, 50Hz, Single Phase Measurement & Control: • Digital Panel Meters: - DC Voltage: 0–30V, 41⁄2 digit precision - AC Current: 0–20A, 41⁄2 digit precision Data Acquisition & Interface: • NI 6602 Timer Cards: - 16 stopwatch channels - Time range: 0.05 to 999.99 seconds - Resolution: 32-bit • 96-channel Digital I/O Card: - Interfaces with buttons, switches, relays • Multifunction I/O (MIO) DAQ Card: - 16 analog inputs - 8 digital I/O lines - 2 analog outputs - Over-voltage protection Computing System: • Intel Pentium 4 Processor, 512MB RAM, 40GB HDD • 15-inch touchscreen monitor for GUI-based operation • Industrial rack-mount cabinet with 5 PCI slots • Online UPS: 1 KVA with 4 hours backup • Laser printer (20 ppm, 1200 dpi) for automated report generation Safety Systems: • Emergency stop push-button • Interlocked drives • Power-on self-tests Application Areas This test rig is built to test electro-mechanical timing components in aircraft, particularly: • Ground Start Sequences: Simulates conditions when an aircraft engine is started on the ground. • Relay & Switch Verification: Tests the working of electrical relays and switches, ensuring they respond within a specific time window. • Backup Systems: Checks emergency circuits that activate during failures. • Micro-switch & Flap Valve Testing: Validates components used in control surfaces like rudders and flaps. These tests help verify the reliability of aircraft systems before actual flight use. Software Architecture Developed using NI LabVIEW, the software is highly visual and intuitive, making it easy to operate even for semi-technical staff. Key Features: • Touchscreen Control: All test operations can be initiated via a touchscreen interface. • Real-Time Monitoring: See voltage, current, and timer readings as they happen. • Report Generation: Automatically generates test reports in Excel format. • Data Logging: Saves test name, date, time, and values to files for future traceability. • Network Enabled: Can connect to a LAN or web interface for remote monitoring. • Safe & Secure: Includes password-based login and session tracking. Calibration & Diagnostics Regular calibration is essential to maintain accuracy. The rig includes provisions for: • In-situ calibration of voltmeters, ammeters, and timers using standard reference devices. • A calibration manual with step-by-step instructions. • Diagnostics software that shows error logs and power-on test results. All instruments are certified with NIST-traceable calibration. Installation, Maintenance & Documentation This test rig is designed for ease of use and serviceability: • Modular design with removable rear covers • Color-coded PTFE wires for safe wiring • All connectors, fuses, relays, and indicators are easily accessible Comprehensive documentation includes: • User Manual • Calibration Manual • Spare Parts List (recommended for 2 years) • Service & Maintenance Manual • Circuit Diagrams • Troubleshooting Guide After-Sales Support & Warranty • Warranty: 12 months from the date of commissioning • Service Support: 10-year commitment on spares and technical help • Installation & Training: Includes on-site training for HAL engineers • AMC Option: Available upon request Designed for Aerospace, Built to Last Whether it’s pre-flight testing or MRO (Maintenance, Repair & Overhaul) validation, this test rig offers unmatched reliability, accuracy, and traceability. Backed by over a decade of collaboration with HAL and built using globally trusted components, the PC-Based Counter Timer Test Rig – Panel 72S.7317 & Timer 72S.6527 is an indispensable tool for any aerospace QA lab or component manufacturing facility.
