Solderless fault insertion test set to enhance ATE operator training

It is the mandate of Automated Test Equipment (ATE) to minimize manual tasking and maximize automation. However, the role of the operator remains crucial to successful deployment of any ATE system. Simple tasks such as setting up the Unit Under Test (UUT), correct probing, potentiometer alignments, etc. must be taught so new operators can establish a basic level of diagnostic capability in the fleet. Current Consolidated Automated Support System (CASS) training hardware is based on F-14 and S-3 platforms which are obsolete, utilize antiquated technology, and are difficult to repair. Such hardware also limits Instructors' ability to insert and remove effective training faults. This paper describes a design concept which provides a robust training test set, including hardware, for operators to learn basic troubleshooting skills and ATE interaction. The US Navy recognized the benefits of such a system to address training deficiencies and initiated the development and acquisition of the CASS Training Set (CATS). The test set includes a variety of training scenarios which are commonly seen in the fleet, including digital tests, analog tests, Operational Flight Program (OFP) loads, alignments, Radio Frequency (RF) tests, diagnostics, etc. The CATS training UUT uses latching relays to induce consistent, repeatable hardware faults, and a microcontroller to produce software faults. Faults are applied and removed through the Test Program Set (TPS) and require no soldering or de-soldering of components. This process automates training fault insertion, extends the life of the training equipment, and provides repeatable fault signatures. Consistent training scenarios ensure lower variance in technical capabilities of course graduates. A complete hardware and software package with the look-and-feel of a fleet avionics asset, but the reliability to withstand a training environment provides a valuable tool to train ATE operators and should be a basic part of any ATE system.