FISC description

General Description

The Concurrent Real-Time Fault Insertion and Signal Conditioning System consists of a rack mount or table-top enclosure with a 3U card nest that contains Fault Insertion and Signal Conditioning (FIS) cards. The card nest contains a proprietary backplane with 21slots. One slot is reserved for the chassis controller and the remaining slots are available for 20 FIS cards, supporting up to 160 lines of five-mode fault insertion.

The enclosure of the Five Mode Fault Insertion / Signal Conditioning System contains the necessary power supplies and cooling provisions for stand-alone operation. Cooling air is drawn in through a front mounted filter assembly then exhauster through the ventilated top cover. When mounted in an equipment cabinet, 1U of space must be reserved above the chassis for exhaust air.

Large channel-count requirements can be supported with Fault Insertion / Signal Conditioning Systems containing multiple 3U card nests stacked within a customized equipment cabinet. These configurations share power and cooling provisions.

Image: Font and rear View of Concurrent FISC Chassis.

Image: A large multi nest Concurrent fault insertion system.

Operation

The Five-Mode Fault Insertion / Signal Conditioning System is interfaced to a Concurrent CS-NI-PCIE-6509 digital I/O (DIO) PCIe card located in the host system. The DIO card controls and monitors the state of the fault insertion relays. Up to 16 3U FIS card nests can daisy-chained from one DIO card. Designed for hardware-in-the-loop design and test environments, the System is supported by Concurrent’s SIMulation Workbench real-time modeling environment. SIMulation Workbench provides an interface to set initial states and establish non-permissible fault combinations. A GUI allows operator selected faults to be set anytime during a simulation run. Faults conditions are also set programmatically for various test scenarios. An API is also available for Red Hawk Linux to provide programming control of all fault conditions through the CS-NI-PCIe-6509.

Functionality

All connections to the Five-Mode Fault Insertion / Signal Conditioning System are through the rear of the enclosure. A chassis controller card is installed in slot-1 of each chassis, and the remaining twenty slots are available for FIS cards. The chassis controller passes relay control and status signals to and from the host system DIO card. The controller interface is through a 50-pin DSUB connector. A second 50-pin DSUB connector is used to daisy-chain multiple chassis together. The last card nest in the chain must have a terminated version of chassis controller card installed.

Signal Interface

The 3U backplane has busses to distribute power, transmit digital control to the FIS cards, and link the three Fault Insertion Busses. The signal lines from the ECU, the host I/O devices and the external loads for each slot pass through the backplane and connect via internal cabling to the rear panel with six 96-pin Cannon DL series Zero Insertion Force (ZIF) connectors. Connectors ECU-1, HOST-1 and LOAD-1 are directed to FIS slots 2-11. Connectors ECU-2, HOST-2 and LOAD-2 are directed to slots 12-21. Normally, the signals from the ECU under test route to the ECU connectors, signals from the I/O devices in the host system rout to the HOST connectors and the external loads and actuators are connected to the LOAD connectors. The faults are inserted on the signal lines between the ECU and LOAD connections. Some FIS cards allow the signal path from the ECU to rout to either the HOST connection or the LOAD connection via a selector relay. Other FIS cards use the HOST connections only for monitoring the signals under load.

There are 20 slots in the FIS backplane for FIS cards and each slot supports eight signal lines. The signal lines for each slot are designated as A, B, C, D, E, F, G,H. So the signal lines in an enclosure are designated as 2A, 2B, 2C, 2D, 2E, 2F, 2G, 2H –through- 21A, 21B, 21C, 21D, 21E, 21F, 21G, 21H.

ECU-xA, HOST-xA and LOAD-xA are the same signal line routed through the FIS card in slot-x, where x=slot 2-21. See Table-1 for signal and pin mapping to the rear connectors.

Fault Busses

The Five-Mode Fault Insertion / Signal Conditioning Systems contain up to six Fault Insertion Busses (FIBs) that are accessible to each FIS card slot. The FIBs are daisy-chained through two rear mounted 9-pin DSUB connectors to link the FIBs between each FIS enclosure. Each signal line can connect to three independent FIBs, (A, B and C). The FIS system is designed to support dual redundant ECU configurations so there are three FIBs for each ECU, (1 and 2). Each FIS card is designed so that half of the signal lines can fault to busses 1A, 1B and 1C and the other half can fault to busses 2A, 2B and 2C. In non-redundant ECU applications, the three ECU-1 fault busses are connected in parallel to the three ECU-2 fault busses so that all signal lines have access to the same fault busses. Therefore, there are three fault busses available in a non-redundant configuration. Each fault line is current limited to 3 Amps to protect the FIB relays and signal paths. All FIBs are accessible to external signal insertion through the rear panel.

FIS Card Fault Insertion Capabilities

Each signal line can be faulted in five* different ways through electromechanical relays:
1.) Direct Short to Fault Bus A
2.) Route signal through a pair of test points on front panel of the FIS card. (Signal Break-out Mode)
3.) Short through 0 Ohm resistor to Fault Bus B (Other values can be installed.)
4.) Short through 0 Ohm resistor to ground (Other values can be installed.)
5.) Open Circuit
6.) Short to Fault Bus C*

A sixth fault mode is possible as Fault Bus C is present in the system. However access to Fault Bus C has not been implemented on existing FIS cards. Additionally, a set of relays for each signal pair A-B, C-D, E-F, G-H are used to connect the ECU to the LOAD.

Signal Break-Out Mode

One of the five fault modes, Break-Out Mode provides for external measurement and manipulation of individual signals. This mode eliminates the need for a break-out-box in the HIL system. There are a series of “Tip Jack” style test points on the front panel of each FIS card. Two test points for each signal line are available. The test points are connected across a shunting relay that is normally closed, to pass the signal through the normal path. When the shunt relay is open, the path is interrupted and the ECU and the LOAD side of the signal are separately available on the front panel.

TPs 1-2 are for signal line A, TPs 3-4 are for signal line B, TPs 5-6 are for signal line C and TPs 7-8 are for signal line D, TPs 9-10 are for signal line E, TPs 11-12 are for signal line F, TPs 13-14 are for signal line G and TPs 15-16 are for signal line H.

FISC Cards

In addition to the test points discussed above, there are a series of LED indicators on each card that indicate the status of the card. In general, RED LEDS indicate that a fault condition has been selected on a signal line. AMBER LEDS indicate a special condition has been set, such as the routing the ECU signals to the LOAD. GREEN LEDS indicate the presence of a signal.

FISC Card Types

All cards types share the same fault insertion capabilities but have various signal conditioning functions. There are 28 types of FIS cards which have been designed for various aerospace and automotive HIL test systems. Below is a list of currently available Fault Insertion and Signal Conditioning Cards. Due to the nature of HIL test systems, many FIS card designs are specific to a customer application.

Card Type and Function	Signal Lines	Model Number
A - PWM Buffer/Filter Conditioning Card	4-SIGNAL LINES	RIQ08313C-041
B - LVDT/RVDT/RESOLVER Excitation w/RMS Converter	4-SIGNAL LINES	RIQ08314D-041
B2 - RMS Converter to Analog – No Fault Insertion	N/A	RIQ10257D-047
B3 – RVDT/LVDT/RSLVR EX GAIN x3	4-SIGNAL LINES	RIQ11795-041
C1 - DISCRETE OUTPUT	8-SIGNAL LINES	RIQ08315D-041
C2 – DUAL POTENTIOMETER	8-SIGNAL LINES	RIQ08315D-042
C3 – COCKPIT SWITCH 10K OHM	8-SIGNAL LINES	RIQ08315D-043
C4 – ESO / GBEV COMBO	8-SIGNAL LINES	RIQ08315D-044
C5 – FAULT INSERTION ONLY	8-SIGNAL LINES	RIQ08315D-045
C6 – RVDT/LVDT/RESOLV FB	8-SIGNAL LINES	RIQ08316C-041
C7 – MAGNETIC CHIP DETECT	8-SIGNAL LINES	RIQ08315D-046
D – SPEED SIGNAL w/COUPLING / BYPASS	4-SIGNAL LINES	RIQ08317D-041
E - RS-422 Switch with No Fault Insertion	N/A	RIQ10051C-041
F– DEC TO DEC INTERLOCK	4-SIGNAL LINES	RIQ08320C-041
G – CROSS CHAN DATA LINK	4-SIGNAL LINES	RIQ08321C-041
H2 – RATIOMETRIC PRES SENSOR 1K OHM	4-SIGNAL LINES	RIQ08319E-041
H3 – RATIOMETRIC RTD 100 OHM	4-SIGNAL LINES	RIQ08319E-042
H4 – RATIOMETRIC 3-LINE RTD	4-SIGNAL LINES	RIQ10070 -041
H5 – RATIOMETRIC PRES SENSOR 1.5K OHM	4-SIGNAL LINES	RIQ08319E-044
H6 – RATIOMETRIC PRES SENSOR 1.8K OHM	4-SIGNAL LINES	RIQ08319E-045
H7 – 2/4-WIRE RTD PROG RES 160 OHM	4-SIGNAL LINES	RIQ08319E-046
H8 – 2/4-WIRE RTD PROG RES 300 OHM	4-SIGNAL LINES	RIQ08319E-047
J – 3-LINE PERM MAGNET ALT	4-SIGNAL LINES	RIQ08323C-041
K – CHARGE COUPLED ACCEL SIMULATOR	2-SIGNAL LINES	RIQ10056B-041
M - ISOLATED TYPE-S TC SIM	4-SIGNAL LINES	RIQ11251A-042
N - RTD / PRESSURE BRIDGE	4-SIGNAL LINES	RIQ11251A-043
O - ISOLATED TYPE-K TC SIM w/CJC (SINGLE CHAN.)	2-SIGNAL LINES	RIQ11251A-044
Q - RMS Current and Voltage Sense for PWM Solenoid / Torque Motor Loads.	4-SIGNAL LINES	RIQ11978A-04D

FIS Card Descriptions

Type A 4-FIS Lines with PWM Buffer/Filter Conditioning Card
This card receives two bi-polar differential signals from the ECU, (one ECU A and one ECU B) and buffers the signals for monitoring by Analog to Digital input channels in the HOST SYSTEM. Each ECU can drive two A to D channels, one for positive going signals and only the other for reverse biased (negative going) signals. Designed to monitor the presence of a signal and provide a scaled down representation of the DC voltage.

Loads are provided by the EXTERNAL LOAD and the ASM relays must be enabled. A red FAULT LED indicates a reversed bias condition.

Type B 4-LINE RVDT/LVDT/RSLVR Excitation w/ RMS Converter Conditioning Card
This card is derives the RMS value of the AC waveform and converts it to a DC value for monitoring by an A to D channel in the HOST SYSTEM. This card is used in conjunction with a C6 card for feedback and routs the ECU signals to I/O simulation or real a sensor in the EXTERNAL LOAD.

Type B2 4-LINE RVDT/LVDT/RSLVR Excitation RMS Converter Conditioning Card
This card is derives the RMS value of the AC waveform and converts it to a DC value for monitoring by an A to D channel in the HOST SYSTEM. This card has no fault insertion capability.

Type B3 4-LINE RVDT/LVDT/RSLVR Excitation Gain X3 w/ RMS Converter Conditioning Card
This card is derives the RMS value of the AC waveform and converts it to a DC value for monitoring by an A to D channel in the HOST SYSTEM. The excitation signal from the ECU is amplified by a factor of three and then routed to the I/O contacts for use by the simulation card in the HOST SYSTEM. This card is used in conjunction with a C6 card for feedback and routs the ECU signals to I/O simulation or real a sensor in the EXTERNAL LOAD.

Type C1-C5 & C7 8-FIS Lines with 1/4 Watt resistor networks (6 different versions).
The functions of this type card are easily changed by modifying the resistor network. Lines A,B - C,D, - E,F - G,H are connected from the ECU contacts directly to the I/O contacts. External loads can be connected in parallel through the ASM contacts. C1 8-LINE DISCRETE OUTPUT, COMMON GROUND C1 supplies 10K resistance across each signal line to ground. A 4:1 voltage divider allows monitoring the signals up to 40VDC with an A to D channel.

C2 8-LINE POTENTIOMETER C2 supplies 5K resistance across each pair of signal lines. A 4:1 voltage divider allows monitoring the signals with an A to D channel. Designed to monitor the excitation value.

C3 8-LINE HIGH INTEGRETY SWITCH DISCRETE INPUT C3 supplies 10K resistance across each pair A,B - C,D - E,F - G,H of signal lines. Switching is provided by relay channels in the host system.

C4 8-LINE DISC IN (No Conditioning) / HIGH INTEGRETY SWITCH C4 supplies no resistance across pairs A,B and E,F and supplies 10K resistance across pair C,D and G,H signal lines. Switching is provided by relay channels in the host system.

C5 8-LINE NO CONDITIONING C5 supplies fault insertion only.

C7 8-LINE MAGNETIC CHIP DETECT / HIGH INTEGRITY SWITCH C7 supplies 10K resistance across pairs A,B and E,F and supplies a reverse biased diode across pair C,D and G,H signal lines. Switching is provided by relay channels in the host system.

Type C6 8-LINE RVDT/LVDT/RSLVR FEEDBACK
C6 supplies no conditioning but allows signal line pairs, A,B - C,D, - E,F - G,H to be connected to either I/O contacts or ASM contacts.

Type D 4-FIS Lines with Coupling/Bypass Conditioning Card
D supplies transformer coupling for signal line pairs, A,B - C,D. A bypass mode of the transformer can be selected.

Type E RS-422 Switch with No FIS Lines
Type E cards have no Fault Insertion or Signal Conditioning. The card is used to switch RS-422 signals only. RS-422 from the ECU is available on DB-9 connectors at the front of the card. The RS-422 from the ECU is also converted to RS-232 and available at the I/O panel.

Type F 4-FIS Lines with ECU to ECU Interlock
Type F cards connect pairs A,B to pairs C,D to connect redundant ECUs together. A 4:1 gain buffer amp is used for monitoring the signal with an A to D channel.

Type G 4-FIS Lines with Cross Channel Communications Link
Type G cards are used in pairs, one for ECU A and one for redundant ECU B. They require use of a backplane jumper on the ASM contacts to connect the TX signal from the ECU A card to the RX signal of the ECU B card and the TX signal from the ECU B card to the RX signal of the ECU A card. The RS-422 like signals are converted from/to TTL signals on the card, routed to the other card through the ASM contacts, or looped back. A fault injection mode can be set where simulated RX data is received from an RS-422 serial channel.

Type H2 4-FIS Lines with Ratiometric 1K Pressure Sensor Simulator
Type H2 cards monitors the excitation voltage with a A to D channel on the HOST SYSTEM and outputs a voltage from a D to A channel in the HOST SYSTEM to the feedback signal pair that simulates the impedance changes of a strain/pressure gauge. The nominal impedance is 1K Ohms across the excitation pair.

Type H3 4-FIS Lines with Ratiometric 4-Wire RTD sensor Simulator
Type H3 cards monitors the excitation voltage with a A to D channel on the HOST SYSTEM and outputs a voltage from a D to A channel in the HOST SYSTEM to the feedback signal pair that simulates the impedance changes of an RTD. The nominal impedance is 100 Ohms across the excitation pair.

Type H5 4-FIS Lines with Ratiometric 1.5K Pressure Sensor Simulator
Type H5 cards monitors the excitation voltage with a A to D channel on the HOST SYSTEM and outputs a voltage from a D to A channel in the HOST SYSTEM to the feedback signal pair that simulates the impedance changes of a strain/pressure gauge. The nominal impedance is 1.5K Ohms across the excitation pair.

Type H6 4-FIS Lines with Ratiometric 1.8K Pressure Sensor Simulator
Type H6 cards monitors the excitation voltage with a A to D channel on the HOST SYSTEM and outputs a voltage from a D to A channel in the HOST SYSTEM to the feedback signal pair that simulates the impedance changes of a strain/pressure gauge. The nominal impedance is 1.8K Ohms across the excitation pair.

Type H7 4-FIS Lines with 2/3/4-Wire 160 Ohm RTD Sensor SimulatoR
Type H7 cards monitors the excitation voltage with a A to D channel on the HOST SYSTEM and simulates the impedance changes of an RTD by providing access to a programmable resistor channel across the excitation pair.

Type H8 4-FIS Lines with 2/3/4-Wire 300 Ohm RTD Sensor Simulator
Type H7 cards monitors the excitation voltage with a A to D channel on the HOST SYSTEM and simulates the impedance changes of an RTD by providing access to a programmable resistor channel across the excitation pair.

Type J 3-FIS Lines with Three Phase Alternator Simulator
Type J switches DC power to either Phase A or Phase C input to the ECU and outputs a frequency, supplied by an HOST SYSTEM frequency channel, to either Phase A or Phase C and Phase B. When power is supplied to Phase A, the frequency should go to Phase B and C. When the power is supplied to Phase C, the frequency should go to Phase A and B. The frequency output is transformer coupled and a transformer bypass mode can be selected. 5-Amp relays are used to switch the simulated alternator power. ECU must support a common AC/DC power ground.

Type K 2-FIS Lines with Charge Coupled Vibration Simulators
Type K card sums up to eight sine wave signals from the arbitrary waveform generator card to form a complex waveform. This waveform can be summed with an on-board white noise source and coupled to the ECU through a capacitor. Low power reed relays are used to connect to the fault insertion bus. The vibration signal is not connected through the backplane but is located on front mounted a twinaxial connector.

Type M 4-FIS Lines with Dual Channel S-Type Thermocouple Sensor Simulator
Type M cards output a voltage from a D to A channel in the HOST SYSTEM that scale down to simulate the voltage output of an S-Type thermocouple.

Type N 4-FIS Lines with Dual Channel RTD and Pressure Bridge sensor Simulator
Type N cards utilizes precision resistor channels in the HOST SYSTEM to simulate a strain bridge by controlling the resistance of one leg of a wheatstone bridge. Also simulates the impedance changes of an RTD.

Type O 2-FIS Lines with Single Channel K-Type thermocouple sensor Simulator
Type O cards output a voltage from a D to A channel in the HOST SYSTEM that simulates the voltage of a K-Type thermocouple. Type O card output is not referenced to ground. It interfaces with mini K-Type connectors.

Type Q 4-FIS Lines with Solenoid / Torque Motor PWM Current Voltage Sense
Type Q is designed to sense the current and voltage of two PWM solenoid / torque motor loads. The card measures the AC value across a 0.1 Ohm resistor in series with the load, provides a gain, than convert the signal to a DC voltage representing the RMS value of PWM current signal. The card also provides the an RMS value of the PWM voltage. Both values are read by A/D channels in the HOST SYSTEM. Designed for signals up to 20V, 2.5A.