Test system constraints with emerging Avionics power requirements

Abstract

The 5th generation of United States Navy and Marine Corps aircraft have Electrical Power System test requirements that far exceed the power capability of power supplies utilized in the Navy's current suite of Intermediate Level Automatic Test Systems (ATS). The Navy's latest ATS, the electronic Consolidated Support System (eCASS), will deploy on thirteen aircraft carriers, eleven amphibious assault ships, and several shore sites. This paper will focus on the hardware and software challenges of integrating a 50 kW DC power supply and a 25 kW DC power supply into eCASS using existing calibration standards and maintenance procedures while allowing dynamic ranges of capability if a component is not available. Power supply paralleling and automated reconfiguration after power supply failures are some of the methods employed to overcome the hardware and software challenges. Addition of the power supplies also requires integration of new environmental monitoring and power subsystem control hardware that interfaces with the existing eCASS power subsystem. Safe and responsive control of the additional power delivery devices is important to ensure operator and facility integration and safety. The allowable heat generated from the ATS augmentation is limited by facility HVAC capacity to ensure the shipboard equipment remains reliable and the ATS operator comfortable. The existing power control unit software of eCASS is expanded on to support new environmental monitoring infrastructure.