TED On-Board: The U.S. Army’s

New Diagnostic Enabler

ARL-TR-362 September 2000

Holly Ingham, Richard Helfman, Edmund Baur, John Dumer, and

Timothy Hanratty

Approved for public release; distribution unlimited.
The findings in this report are not to be construed as an

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Destroy this report when it is no longer needed. Do not

return it to the originator.
ARL-TR-362 September 2000

Army Research Laboratory

Aberdeen Proving Ground, MD 21005-5425

TED On-Board: The U.S.

Army’s New Diagnostic Enabler

Holly Ingham, Richard Helfman, Edmund Baur, John Dumer, and

Timothy Hanratty

Computational and Information Sciences Directorate

U.S. Army Combined Arms Support Command

3901 A Ave

FT Lee, VA

Sponsored by

Approved for public release; distribution unlimited.
The U.S. Army is improving its logistic information systems so that it can

continue to meet the logistics needs of future combat operations. This

report describes a system that will provide engine status information on

the M1A1 Abrams main battle tanks to battalion and brigade logistics

maintainers. The system will reside on board the tank and is called TED

On-Board. TED On-Board is an extension of a currently fielded

(off-board) diagnostic system called TED (Turbine Engine Diagnostics).

Abstract

ii
iii

Contents

1. Introduction 1

2. Turbine Engine Diagnostics 3

3. TED On-Board System 5

3.1 Objective ..................................................................... 5

3.2 Hardware .................................................................. 5

3.3 Software ..................................................................... 6

3.4 Benefits ..................................................................... 7

3.5 Current Progress ......................................................... 8

4. Conclusions 12

References 13

Glossary 14

Distribution 17

Report Documentation Page 19

Figures

1. TED On-Board hardware configuration .................................... 6

2. Interface showing received message from TED On-Board ............ 9

3. GRC ASA for Fort Hood demonstration ................................. 10

4. Sample data from Fort Knox test ............................................. 11
1

1. Introduction

Advanced electronic and information technologies are converging in all areas

of the marketplace. The U.S. Army has recognized the tremendous advances

being made and is incorporating many of these technologies into its weapon

systems to remain the most technically superior and sophisticated fighting

force in the world. Turbine Engine Diagnostics (TED) On-Board (TOB) is

one of several Army programs designed to bring Army logistics into the

Information Age. Army logistics systems must be responsive to the fast pace

of modern warfare. The Army’s current logistics operations, however, are

not adequate to support the continuous high-speed tempo of future combat

operations. The phrases “sneaker net” and “swivel chair net” appropriately

describe the state of Army logistics information systems at the brigade level

and below.*

During tactical operations, logistics information flows in two directions:

upward and downward. Platform status information moves from the

weapon platform upward into the command and support systems. The

command structure uses the data to determine factors such as combat readiness. The support structure uses the information to schedule needed maintenance or repair actions and to coordinate supply movements. The downward flow of logistics messages to the platform may contain status update

requests or may provide notification of maintenance or supply activities.

As part of an effort to have a weapon system provide platform status information, an increasing number of recently developed systems have required

various levels of built-in test and diagnostics equipment to decrease the

reliance on general-purpose test equipment. Unfortunately, until now, the

Army has not instituted any system, policy, or standards to guide materiel

developers to an effective embedded diagnostics program.

In July 1997 representatives from the Army Materiel Command (AMC),

Deputy Chief of Staff for Logistics (DCSLOG), Deputy Chief of Staff for

Operations and Plans (DCSOPS), Assistant Secretary of the Army, Research

Development and Acquisition (ASARDA), and Training and Doctrine Command (TRADOC) directed that the Program Manager for Test, Measurement, and Diagnostic Equipment (PM-TMDE) develop an Army-wide strategy for emplacing and embedding diagnostics on all Army equipment [1].

This directive resulted in the Army Diagnostic Improvement Program

(ADIP) Master Plan. By April 1998, the Department of the Army (DA) stated

that “embedded diagnostics and prognostics are tenants of Army XXI and

the Army After Next” [2]. It directed that this become a requirement within

*“Sneaker set” refers to the methods of transferring information between computers at

different echelons by manually carrying floppy disks. “Swivel chair net” refers to the method

of transferring information between computers at the same echelon by retyping information

from one computer to another computer.
2

every Operational Requirements Document, that program managers (PMs)

include embedded diagnostics on all new and retrofit equipment, and that

they coordinate this action with PM-TMDE [1]. The Army Acquisition Executive also directed that embedded diagnostics become part of the PM’s

acquisition strategy and that it be coordinated with PM-TMDE [3].
3

2. Turbine Engine Diagnostics

Long before ADIP was proposed, the Ordnance Center and School (OC&S),

in coordination with the U.S. Army Research Laboratory (ARL), took the

Army into the world of digitized diagnostics. Shortly after the Gulf War, it

became apparent that the M1A1 Abrams main battle tank, albeit the epitome

of lethality and survivability on today’s battlefield, is expensive to operate,

support, and maintain. With the downsizing of the Army, experienced mechanics are quickly vanishing, along with their expertise. This, coupled with

the rising costs of replacement parts and fuel, dictated the need for action if

the Army was going to keep the M1A1 operational in the years to come.

Since parts and fuel are dictated by the economy, the OC&S and ARL proposed focusing on the repair costs. Together, they developed the expert system TED to help the M1A1 tank’s mechanic diagnose and repair the M1A1

tank’s engine and transmission.

The development of the system began in 1991, and by 1994, TED was fielded

for testing to the National Guard. The National Guard continued to incrementally field TED, and by 1996, the Army began fielding TED to all direct

support (DS) units.

TED is a combination of hardware and software that together create a powerful diagnostic tool for all levels of mechanics who maintain and repair the

M1A1 Abrams main battle tank. The hardware consists of a piece of diagnostic equipment called an automated breakout box (ABOB). The software

consists of a number of expert modules that are accessible to the mechanic

through a menu-driven interface. To use TED as a diagnostic aid, the mechanic would need an ABOB, a laptop, and the TED software.

Mark Kregal from ARL developed the ABOB, which is an extension of the

standard issue breakout box (BOB). His main purpose was not to add unnecessary specialized equipment to the mechanic’s inventory. Hence, the

ABOB has all the same functionality as the original BOB with the additional

feature of reading the electronic control unit’s (ECU’s) signals in a fraction

of a second, digitizing them, and passing them on to the TED software for

interpretation.

The TED software is divided into three main modules: TED, ABOB, and

RPSTL (repair parts and special tools list). The TED module separates the

troubleshooting and maintenance routines into three specific areas: inspections, operational checks, and maintenance. The ABOB module provides

the mechanic an interface to the ABOB by automating the manual tasks

associated with the BOB and by providing instantaneous access to all the

engine’s voltage signals. The ABOB software automatically monitors the

voltage signals, and when a fault occurs, the mechanic is notified of the

problem through the on-screen interface. The RPSTL module provides the
4

mechanic access to the extensive parts ordering information for the Abrams

engine and transmission.

As a follow-on to the TED program, ARL, with the support of the U.S. Army

Combined Arms Support Command (CASCOM), has developed a diagnostic enabler and embedded it on board the tank. This diagnostic enabler,

hereon known as TED On-Board, is based on the automatic diagnostic capability found in TED.

CASCOM has been a strong supporter of the TED program, promoting it as

the Army’s first true interactive electronic technical manual (IETM). When

ARL expressed the desire to bring the automatic diagnostic capabilities of

TED on board the tank, CASCOM was quick to support and promote the

program, using TED On-Board as an example of a retrofitted on-board IETM

in the Capstone Requirements Document for the ADIP.
5

3. TED On-Board System

3.1 Objective

The goal of embedding a diagnostic system on board a weapon system is to

perform diagnostics on the move and report the results to logistics personnel. With these goals met, the Army would realize a decrease in repair-cycle

time, an increase in combat readiness, and a reduction in operation and

support costs.

ARL has long had the desire to collect operational data from the tank so as

to perform more accurate diagnostics. The data obtained on board the tank

as it performs in varying conditions and environments will help identify

and track trends of operational behavior, paving the way for prognostics.

The TED On-Board system continuously monitors all 32 signals from the

engine and reports failures as they occur. In addition, periodic health checks

can be performed automatically as operational conditions warrant. This

action will differentiate and expedite repairs.

The onboard system must communicate the information obtained from the

engine to tank crew, operators, commanders, and logistics personnel. TED

On-Board will use a small one-line liquid crystal display (LCD) to immediately inform the crew and operator of potentially dangerous faults. In addition, it will link directly to the Force XXI Battle, Command, Brigade, and

Below (FBCB2) system, where available, or to the tank’s Single-Channel

Ground and Airborne Radio System (SINCGARS) via a serial cable connection. The interface between the onboard system and the FBCB2 or radio

enables the vehicle to transfer the engine’s condition to other tanks and key

logistics personnel.

3.2 Hardware

The challenges facing ARL in incorporating TED’s capability on board the

tank required the system to be compact, rugged, and efficient. The confines

of the tank dictated that the footprint for the TED On-Board be much smaller

than that of the original ABOB. Power constraints further restricted the system to be a low-load unit that can operate on tank voltage. Maintaining

compatibility with all M1 tanks, the system uses SINCGARS, the communications system common to the entire fleet of M1 tanks, to communicate off

the tank.

To meet these challenges, ARL chose a PC/104 bus architecture. The PC/

104 bus architecture provides all the advantages of the PC architecture in a

small rugged package, with minimized power consumption and heat dissipation. The PC/104 boards are small (3.6 in. × 3.8 in.) and contain self-
6

stacking connectors to allow multiple boards to be mounted in a low-profile

design just 0.6 in. apart. The solid pin-and-socket connectors make the PC/

104 architecture significantly more rugged than its competitive embedded

PC options. The PC/104 signals have a reduced bus drive, only 4 mA, resulting in minimal power consumption and heat dissipation.

PC/104 boards have been an open standard since 1992 and have been successfully used in many commercial applications, including space-constrained

vehicular, mobile, and avionics systems. In addition, a wide number of PC/

104 CPU configurations are available. A 486 DX processor with a keyboard

input, two RS232 communication ports, and a parallel port was chosen for

the four TED On-Board prototypes that ARL currently has. An analog-todigital (A/D) board, along with the multiplexer board used in the ABOB,

provides the capability of obtaining the analog signals from the standard

128-pin connector and converting them to digital for use by the system. A

video graphics adapter (VGA) board was added to the system, as well as a

2.1-GB hard drive to facilitate debugging. Finally, a power supply that can

use input voltage from 6 to 30 V was used to power the system. The final

configuration is shown in figure 1.

3.3 Software

To conserve power, reduce complexity, and lower costs, most embedded

systems use a rudimentary operating system such as DOS. In the long term,

TED On-Board will also use a similar type of operating system. ARL decided that the quickest, most economical way to develop the TED On-Board

software was to start with a proven product, TED, and adapt it to meet the

needs of an onboard system. The automated diagnostic software in TED is

written in Inprise’s DELPHI, a Windows-based object Pascal language.

Therefore, in the near term, the TED On-Board software was built and runs

in the Windows operating environment.

Figure 1. TED OnBoard hardware

configuration.
7

The Windows operating environment affords many advantages in building

a system that the DOS environment lacks. The first and most obvious is a

well-defined and easily understood user interface. Although not important

for the final onboard system since it will contain no visual interaction with

the user, Windows is vital in the development process to help fix problems

and refinement.

The ABOB software monitors the 32 signals coming from the ECU until a

fault has been detected. At this point, the user is notified and the system

stops looking for out-of-tolerance data. In contrast, an onboard system needs

to continue monitoring engine signals even after a fault is discovered. It

must know how to interpret one fault while continuing to monitor for other

faults. TED On-Board expands the ABOB software to incorporate this

capability.

In the final configuration, the TED On-Board system will continually monitor all 32 signals from the engine, reporting faults as they occur. When a

fault is detected, the system determines which subsystem is affected and

the possible tools and components needed to repair it. The system combines all this information into a message that is sent off board to all appropriate personnel through the radio interface.

3.4 Benefits

The benefits associated with such a system, especially when it is linked to

an integrated maintenance management system, include increased combat

readiness, decreased operation and support (O&S) costs, and the ability to

anticipate maintenance needs.

TED On-Board will increase combat readiness by keeping the tank crew,

tank commander, and logistics personnel informed about the operational

status of the tank. TED On-Board provides commanders with an accurate

assessment of their equipment at all times, allowing them to establish priorities and immediately marshal the exact resources needed to maintain a

high level of combat readiness. The system does this through the reporting

of out-of-tolerance engine data as well as engine health check data to all

levels of command using the FBCB2 system. This knowledge becomes especially important during offensive operations because it will permit fixing

on the move, as opposed to the former practice of leaving disabled equipment until supporting maintenance elements respond.

O&S cost savings are discovered through improving system diagnostics,

reducing repair cycle time, eliminating expensive tools and test equipment,

minimizing parts usage, monitoring engine health in real time, and maximizing the capabilities of maintenance personnel. Based on the same diagnostic algorithms found in TED, the TED On-Board system is expected to

reduce the no-evidence-of-failure (NEOFF) rate by at least 50 percent, thus

reducing the unnecessary use of parts and personnel. TED On-Board will

decrease the repair cycle time by reporting failures as they occur to combat
8

service support (CSS) personnel. Onboard diagnosis eliminates the need

for much of the off-board diagnostic equipment currently used. Real-time

health monitoring performed by the system will track an engine’s performance, and as it declines, the system will request routine maintenance to

prevent a catastrophic failure from occurring.

The TED On-Board link to the Global Combat Support System Army (GCSSA) will provide an integrated CSS solution that especially leverages relevant CSS functions. Armed with the information from the onboard diagnostics, the logistics manager can order and direct maintenance assets to

most effectively and efficiently fulfill the mission. The result is anticipatory

logistics.

3.5 Current Progress

The communications portion of the TED On-Board system was demonstrated at the annual Federated Laboratory Symposium at the University of

Maryland, College Park, campus in February 1999. The demonstration used

the ARL prototype communications vehicle as the tactical operations center

(TOC), located at the College Park campus, and a full-up power pack (FUPP),

located approximately 4 miles away at the ARL-ALC headquarters. A software program developed by ARL to visualize the TED On-Board data was

downloaded on a PC in the communications vehicle and received data via

the onboard SINCGARS radio. The TED On-Board system was linked to

the FUPP and broadcasted the diagnostic data via a SINCGARS radio to the

communications vehicle at College Park. This same scenario was used for a

congressional demonstration given at ARL-ALC in March 1999. The only

difference was that the communications vehicle and the FUPP were colocated

at the ARL-ALC compound.

ARL demonstrated the diagnostic and communication capabilities of the

TED On-Board system in March 1999 at Aberdeen Proving Ground (APG),

MD. The TED On-Board prototype was temporarily mounted in an M1A2

tank and linked to the ECU and to the tank’s SINCGARS. A tent, under

which another SINCGARS was connected to a laptop, was set up to represent a command post. The laptop was loaded with a software program developed by ARL to receive and display the diagnostic information sent by

the TED On-Board system. The test consisted of starting and running the

tank, inducing a fault on the fly, and communicating the diagnostic information from the tank to the command post over the SINCGARS with the

use of a predetermined message format. Figure 2 is an example of the information received.

ARL has been working closely with General Research Corporation (GRC),

the main contractor under the ACT II contract with the Army, to develop a

standardized message format for embedded diagnostic systems. The message format must be flexible enough to support different types of diagnostic and maintenance information, must be portable (i.e., operating system
9

independent), and must be easily updated to accommodate changes in diagnostic equipment and Army maintenance doctrine. XML (Extensible

Markup Language) is being considered for the message format because it is

such a powerful tool for data representation, storage, modeling, and

interoperation.* GRC, with input from ARL, has developed a documenttype definition (DTD) for the TED On-Board data. A DTD is the validation

specification, or grammar, for the language defined for data using the XML

format. GRC built an Anticipatory Support Architecture (ASA) for use at a

forward support company to receive and assess embedded diagnostic data

from weapon system platforms using the XML format. In late July 1999, at

APG, GRC demonstrated this architecture via an M1A2 tank equipped with

a TED On-Board system as its data source. The TED On-Board correctly

identified engine faults and communicated those faults to a simulated TOC

equipped with the GRC ASA. The ASA received the engine fault data and

identified the unit and vehicle affected.

After the July demonstration, GRC expanded the ASA to include recommendations of tasks, work orders, and repair parts required to sustain the

weapon system in a mission-capable condition. These recommendations

Figure 2. Interface

showing received

message from TED

On-Board.

*XML is actually a metalanguage that gives the power of representing the contextual

meaning of data. These qualities of XML, in addition to it being a subset of SGML (the DoD

standard format), make it a prime candidate for this application.

Engine Health Check

NPI Speed I/Window PIS Level WF Level Cutoff Sol Rel Volts

NH Speed T/Start IGV Error WF Error Start Timer T1

Fault Reasons

Reset

Show Fault Diagram

PM I Abort PM II Fault PM III Fault PM IV Fault

Fault Modems

Engine Shutdown State

Normal Shutdown

Unscheduled Shutdown

Low oil

Engine Start State

Starter Only

Start Attempt

Engine Running

Day Power % Engine Horsepower Accuracy +/– 10%

Standard Day Power % Engine Horsepower Accuracy +/– 10%

Calculated Using TI and PTS Actual
10

will then be forwarded to the battalion command and to GCSS-Army. This

effort was demonstrated at APG in December 1999 with the use of the same

configuration as the July demonstration. An additional demonstration occurred at Fort Hood, TX, in January 2000 with two M1A2 Abrams tanks

equipped with TED On-Board systems. The demonstration was essentially

the same as the December demonstration at APG, except for the additional

tank. Figure 3 shows the ASA as it stood for the January demonstration.

These demonstrations established that linking TED On-Board health checks

and diagnostics to a prototype of the GCSS-Army is feasible, effective, efficient, and capable of achieving anticipatory logistics.

Of the four TED On-Board prototype systems, three were used in a prolonged field experiment at Fort Knox, KY, from June to December 1999. The

fourth system remained at ARL, where it was used for further testing and

demonstration. The experiment consisted of two separate tests: one conducted by PM Abrams and one conducted by CASCOM. Two of the TED

On-Board systems were mounted on board M1A2 tanks involved in regular field exercises, with the third system available as backup. The PM’s goal

was to test the system for possible inclusion in the redesigned hull network

box (HNB) for the M1A1. The PM was interested in the ruggedness of the

system and the accuracy of the diagnostics. Figure 4 shows a sample of the

data that were collected. Using TED On-Board as its data source, CASCOM

was interested in testing the communications and database portions of

GCSS-Army.

Figure 3. GRC ASA for Fort Hood demonstration.

TCP/IP LAN

Projection

video Laptop

GCSS-Army CR

GCSS-Army Lab

Handheld

Ops Net

EBC interface

TED On-Board Int

PSA/ALOC

FBC B2

BOB

TED Sim/int

TED On-Board Int

Projection

video

Win

NT

Win

NT

Win

NT

Projection

video

TOC

COA

GCSS-A

ALOC

PSA

AAA

Win

95

50 ft 300 ft

RIFF

(Across North Ave)

TED On-Board

SINCGAR Modem

Handheld

Ops Net

M1A1

M1A1

Behind GCSS-Army Lab

(North Ave)

Handheld

Ops Net

SINCGARS

Modem

110 V AC

RS-232

Simulated

FUPP TED
11

Figure 4. Sample data

from Fort Knox test.

**** TOB Version 08   Jun 1999 ** ** at: 6/22/99 7:13:53 AM

ECU ON at: 6/22/99 7:13:54 AM

ECU model = DECU at: 6/22/99 7:13:54 AM

Start Attempt at: 6/22/99 7:20:45 AM

Engine running at: 6/22/99 7:21:13 AM

Begin PM II Condition at: 6/22/99 7:22:50 AM

IGV Error: at: 6/22/99 7:22:50 AM

End PM II Condition at: 6/22/99 7:22:51 AM

Normal Shutdown at: 6/22/99 7:37:40 AM

Start Attempt at: 6/22/99 7:39:10 AM

Engine running at: 6/22/99 7:39:35 AM

Begin PM II Condition at: 6/22/99 7:42:28 AM

IGV Error: at: 6/22/99 7:42:28 AM

End PM II Condition at: 6/22/99 7:42:28 AM

Normal Shutdown at: 6/22/99 7:45:58 AM

  TOB Version 08 ** ** Jun 1999 **** at: 6/22/99 8:44:32 AM

ECU ON at: 6/22/99 8:44:34 AM

ECU model = DECU at: 6/22/99 8:44:34 AM

Start Attempt at: 6/22/99 9:54:59 AM

Engine running at: 6/22/99 9:55:25 AM

Normal Shutdown at: 6/22/99 10:09:03 AM
12

4. Conclusions

The TED On-Board system prototype design is still too bulky to be used

practically in the M1 fleet of vehicles. Ideally, the components of the TED

On-Board system can be incorporated onto one card that can be added to

the HNB. ARL contacted personnel from PM Abrams who are involved in

designing the proposed new HNB. They were given a demonstration of the

TED On-Board system in March 1999 and are in favor of incorporating the

system into the new HNB.

ARL would like to expand the capabilities of TED On-Board to include other

systems besides the engine and transmission. Expanding the hardware to

read 128-pin data and incorporating the data into the HNB would give the

system access to vital information such as fuel levels, oil pressure, etc. The

capability of reading 128-pin data would also allow the system to connect

to any Army vehicle system that contains a standard 128-pin connector. The

final hurdle would be developing the diagnostic algorithms to interpret the

signals received.
13

References

1. Department of the Army, Diagnostic Improvement Program Master Plan, PMTMDE, 4 January 1998.

2. DA memorandum, Accelerated Application of Embedded Diagnostics, 30 April

1998.

3. SA RD-SI memorandum, Horizontal Technology Integration and Accelerated

Application of Embedded Diagnostics on Army Equipment, 8 June 1998.
14

Glossary

ABOB automatic breakout box

A/D analog to digital

ADIP Army Diagnostic Improvement Plan

AMC Army Materiel Command

APG Aberdeen Proving Ground

ARL Army Research Laboratory

ASA Anticipatory Support Architecture

ASARDA Assistant Secretary of the Army, Research Development

and Acquisition

BOB breakout box

CASCOM Combined Arms Support Command

CSS combat service support

DA Department of the Army

DCSLOG Deputy Chief of Staff for Logistics

DCSOPS Deputy Chief of Staff for Operations

DS direct support

DTD document-type definition

ECU electronic control unit

FBCB2 Force XXI Battle, Command, Brigade, and Below

FUPP full-up power pack

GCSS-A Global Combat Support System Army

GRC General Research Corporation

HNB hull network box

IETM interactive electronic technical manual

LCD liquid crystal display

NEOFF no evidence of failure

OC&S Ordnance Center and School

PM Program Manager

PM-TMDE Program Manager for Test, Measurement, and Diagnostic

Equipment
15

RPSTL repair parts and special tools list

SINCGARS Single-Channel, Ground and Airborne Radio System

TED Turbine Engine Diagnostics

TOC tactical operations center

TRADOC Training and Doctrine Command

VGA video graphics adapter

XML Extensible Markup Language
17

Distribution

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Attn ODDRE (R&AT)

The Pentagon

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Ofc of the Secy of Defns

Attn OUSD(A&T)/ODDR&E(R) R J Trew

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Washington DC 20301-7100

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NSN 7540-01-280-5500 Standard Form 298 (Rev. 2-89)

Prescribed by ANSI Std. Z39-18

298-102

TED On-Board: The U.S. Army’s New Diagnostic

Enabler

September 2000 Interim, Jan 1998–Jan 2000

The U.S. Army is improving its logistic information systems so that it can continue to meet the

logistics needs of future combat operations. This report describes a system that will provide engine

status information on the M1A1 Abrams main battle tanks to battalion and brigade logistics

maintainers. The system will reside on board the tank and is called TED On-Board. TED On-Board

is an extension of a currently fielded (off-board) diagnostic system called TED (Turbine Engine

Diagnostics).

Embedded diagnostics, logistics

Unclassified

ARL-TR-362

0TEP20

611102.H48

AH48

N/A

ARL PR:

AMS code:

DA PR:

PE:

Approved for public release; distribution

unlimited.

23

Unclassified Unclassified UL

3901 A Ave

FT Lee, VA

U.S. Army Research Laboratory

Attn: AMSRL-CI-CT hollyo@arl.army.mil

U.S. Army Combined Arms Support Command

19

Holly Ingham, Richard Helfman, Edmund Baur, John

Dumer, and Timothy Hanratty

email:

2800 Powder Mill Road

Adelphi, MD 20783-1197