Instrument replacements and obsolescence issues of legacy test systems [for avionics]

Discusses Boeing solutions to obsolescence issues in legacy test systems and their replacement test systems used in production and return-to-service testing of complex avionics for commercial airplanes. The study reported combines test capability of two different legacy test systems into one new ATS design. In addition to obsolescence solutions, several analytical studies to reduce TPS (test program set) variability in legacy test systems are presented. Highlights of this ATS variability study identify the sources of variability and provide solutions, including detailed cam travel variability charts, metallurgical spectrum charts, and microphotographs. A trade study compared cost of replacement versus implementing some simple scheduled maintenance processes. This paper discusses challenges and solutions for these areas of common interest for legacy ATS.