A Fleet of DAQ Systems for all Testing Needs: HBM Supports Sikorsky in Complex Helicopter Testing

Gearboxes and transmission are highly critical components. Dedicated test stands are set up to allow testing of the entire lifespan of a transmission, simulating loads coming from the rotor and extreme conditions such as over torques or oil leaks. Measurements in these areas tend to focus on torque, rotation, pressure and temperature. In addition, all actuators, hydraulic and control systems have a fundamental role in granting control of the machine and in no case should fail or malfunction.

This means that one of the most important testing scenarios features temperature, load and pressure measurements. On a slightly larger scale during Environmental test campaigns single components or even entire airframes may be tested in climate chambers to determine their response to extreme cold or heat. This is because it is crucial to ensure all the machine’s critical components remain efficient and responsive even under unpleasant environmental situations.

A Single Solution for Data Acquisition

Now imagine being an Instrumentation Engineer, receiving the task to specify a data acquisition system for a very large set of test applications required in the development of a helicopter. This was the challenge that the Sikorsky Ground Test Instrumentation Team faced. Many test scenarios, many requirements, and one target: find a single data acquisition system fulfilling all of this. Sikorsky turned to HBM as a partner for their new DAQ system. Therefore, a project team formed by the Sikorsky Ground Test Instrumentation personnel and HBM experts from USA and Germany analyzed the requirements and started development of an overall system concept.

In the design phase, there were some vital requirements stated by Sikorsky that would go on to play a major role in the final DAQ System definition.

• The system must support all possible sensors and transducers used in the company’s laboratories, with individual per channel configurable sensor types, filters, and sample rates running on the embedded hardware. On top of that, digital avionics bus data need to be logged from MIL-STD-1553 and ARINC-429.

• The data acquisition system must be accommodated in a specialized cabinet known as the Shell.

• The shell has to be mobile, compact, of robust design, and offer an efficient interface with the data acquisition system. Ethernet and wireless connectivity are needed.

• The shell must be rapidly reconfigurable by adding, removing or switching between measurement modules without needing tools, with a maximum reconfiguration time of 5 minutes.

• Measurement modules must be able to operate outside the Shell, in the form of compact, portable DAQ systems.

• The system must be able to interface with the company’s existing network infrastructure via wireless Ethernet connection, uploading data to share while the test is running.

• The system must be able to interface with existing Sikorsky’s control systems and safety/shutdown systems, ensuring interlock connectivity and cycle counting capability.

QuantumX Data Acquisition System

A Custom Made DAQ Station

With HBM's equipment, the Sikorsky Ground Test Instrumentation Team now deploys a fleet of DAQ systems satisfying all of their testing needs. The custom design allows unprecedented rapid reconfiguration for all of their different test setups. In addition, the software, catman®AP running on the CX22B-W data recorder features specific functions for fatigue testing such as cycle-based data recording and multiple parallel recorders.

Thanks to the flexibility and scalability of the QuantumX DAQ System, high channel count applications are now possible by linking multiple data system shells together, synchronizing thousands of channels and storing them in a single file.

About Sikorsky

From the flight of the world's first practical helicopter in 1939, Sikorsky has remained the industry leader through its commitment to innovation, excellence and safety.

Sikorsky (a Lockheed Martin Company) provides military and rotary-wing aircraft to all five branches of the U.S. armed forces along with military services and commercial operators in 40 nations.

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