Innovative TPS Development Solutions to Reduce the Time, Cost, and Physical Footprint of Supporting Avionics

Abstract

Two significant issues facing Naval Aviation avionics support are “No Fault Found” conditions and Original Equipment Manufacturers (OEMs) ceasing support of avionics systems. With older avionics requiring more labor hours for troubleshooting and OEMs no longer providing support to repair older avionics, the increase in turnaround time has depleted supply stock of UUTs. As a result, Naval Program Management Air (PMAs) and Fleet Support Teams (FSTs) have to endure negative cost and schedule impacts. In order to support troubleshooting and repair at the Intermediate (I)-level for the H-1 Wiring Integration Assemblies (WIAs), the Cherry Point Development Team developed a solution using a universal cable design to support testing of 43 WIAs. The design utilizes thirty-seven (37) Test Adapter Cables (TACs) to interface between the WIA and the A WTS-02 whereas the OEM design required 500 TACs. Using the universal design solution lead to a 90% reduction in the number of cables, 83% reduction in cost, and a 57% reduction in schedule. This design provides Fleet users the capability to repair and declare Ready for Issue (RFI) WIAs directly in the field. Additionally, there is no testing or troubleshooting support available for the AV-8 Air Data Computer (ADC) Chassis. Currently, the I-level utilizes a process of elimination to identify if the fault is in the ADC chassis or the Circuit Card Assemblies (CCAs). In comparison, the depot maintainers rely on a Digital Multi Meter (DMM) to perform continuity checks and perform visual checks for isolation. The maintainers follow the process until the ADC passes; otherwise, the asset is deemed non-repairable and thrown away. To reduce the hours spent on testing the ADC Chassis, the Cherry Point Development Team designed a Test Program Set (TPS) utilizing the high density circuit switching offered by Eclypse International. Instead of having fourteen (14) cables connecting the ADC Chassis to the A WTS-02, the design utilizes fourteen (14) mock CCAs, four (4) ribbon cables, and two (2) Test Adapter Cables (TACs). This innovative TPS design reduces hookup time, physical footprint and cost for the AV-8 team.