Patent ID: 12187458

DETAILED DESCRIPTION

The illustrative embodiments recognize and take into account one or more different considerations. For example, the illustrative embodiments recognize and take into account that it would be desirable to test components in a fuel tank system, the completed wing assembly being assembled with other components to form completed aircraft.

The illustrative embodiments recognize and take into account that with the use of optical components within the cavities of the fuel tank structures, testing of fuel tanks can be performed at an earlier stage as compared to currently used electrically based sensors inside fuel tanks that use wired connections. The illustrative embodiments recognize and take into account that these components include, for example, optical fuel tank sensors, fiber-optic bundles, and other components.

The illustrative embodiments recognize and take into account that currently after integration of the fuel tank sensors, fiber-optic bundles, and other components, a mechanism for verifying the operation of sensors and sensor connections is unavailable without assembling the entire aircraft and initiating a full up system test.

The illustrative embodiments recognize and take account, however, that with an optical based sensor system, optical data concentrators can be connected to the optical sensors in the fuel tanks using optical fibers. The optical data concentrators can receive optical signals from the optical sensors.

As used herein, the phrase “at least one of,” when used with a list of items, means different combinations of one or more of the listed items can be used, and only one of each item in the list may be needed. In other words, “at least one of” means any combination of items and number of items may be used from the list, but not all of the items in the list are required. The item can be a particular object, a thing, or a category.

For example, without limitation, “at least one of item A, item B, or item C” may include item A, item A and item B, or item B. This example also may include item A, item B, and item C or item B and item C. Of course, any combinations of these items can be present. In some illustrative examples, “at least one of” can be, for example, without limitation, two of item A; one of item B; and ten of item C; four of item B and seven of item C; or other suitable combinations.

Thus, the illustrative embodiments provide a method, apparatus, and system for testing a fuel tank system.

With reference now to the figures and in particular with reference toFIG.1, a pictorial illustration of a fuel tank system testing environment is depicted in accordance with an illustrative embodiment. In this illustration, fuel tank system testing environment100includes wing102, which is a wet wing. In which the structure of wing102defines a cavity for fuel tank104within wing102. As depicted, wing102in a phase of manufacturing in which various components have been installed for fuel tank104. In this illustrative example, components such as optical sensors and optical fibers have been installed inside fuel tank104. As depicted, optical fuel quantity data concentrator106is located outside of the fuel tank104.

At this phase of manufacturing, wing102has not yet been attached to other components such as a fuselage of the aircraft. Additionally, seals and other parts that reduce access to components within fuel tank104and not yet been installed in this phase of manufacturing of the aircraft.

Testing of these components for fuel tank104can be performed even though optical fuel quantity data concentrator106has not yet been connected to the assembled avionics of aircraft. Further this testing can occur before seals and other parts limiting access to interior108of fuel tank104are installed.

In this example, the testing can be performed using fuel tank system analyzer110operated by human operator112. Fuel tank system analyzer110comprises laptop computer114, network interface115, power supply118, and controller116.

As depicted, laptop computer114is connected to network interface115by universal serial bus cable117. In turn, network interface115is connected to controller116by cable124, which is a Y-cable in this example. As depicted, one end of cable124connects to controller116and the split ends both connect to network interface115. Power supply118is connected to controller116by cable126. Controller116is connected to optical fuel quantity data concentrator106by test cable Channel A120and test cable Channel B122. These two cables form a Y-cable that connects optical fuel quantity data concentrator106to controller116.

Power supply118sends electrical power in the form of an electrical current though cable126to controller116. Controller116then routes power to optical fuel quantity data concentrator106through test cable channel A120or test cable Channel B122. When the electrical current is received by optical fuel quantity data concentrator106, optical fuel quantity data concentrator106sends an optical signal to optical fuel sensors that are connected to optical fuel quantity data concentrator106by optical fibers.

The optical signal sent by optical fuel quantity data concentrator106is converted into electrical power by photovoltaic converters located within each optical fuel sensor. The converted electrical power is used to power the sensors. In this illustrative example, powered fuel sensors will automatically start producing data readings and will convert the raw sensor data back into an optical signal and transmit it back to optical fuel quantity data concentrator106via the same optical link used to power the sensor.

The electrical current from power supply118is routed through either test cable Channel A120or test cable Channel B122when a switch in controller116is closed to allow the electrical current to flow from controller116to optical fuel quantity data concentrator106. The switch can be, for example, a manual switch operated by human operator112or an electronic switch controlled by laptop computer114.

In response a set of the optical sensors send a set of optical response signals to optical fuel quantity data concentrator106. As used herein, a “set of,” when used with respect to items, mean zero or more items. For example, a set of optical sensors is zero or more sensors. In other words, the set can be a null set in which none of the optical sensors return optical response signals.

Optical fuel quantity data concentrator106generates test data in response to receiving the set of optical response signals. This test data is sent to laptop computer114through test cable Channel A120or test cable Channel B122to controller116and then to laptop computer114for analysis. Laptop computer114determines the state of the optical sensors based on the test data.

With reference toFIG.2, an illustration of a block diagram of a fuel tank system testing environment is depicted in accordance with an illustrative embodiment. Fuel tank system testing environment100is an example of one implementation of fuel tank system testing environment200inFIG.2.

In this illustrative example, fuel tank system204for aircraft206comprises fuel tanks208. As depicted, aircraft206is a partially assembled aircraft. Fuel tanks208can be selected from at least one of a wing for aircraft206, a fuselage section for aircraft206, or some other suitable component that is assembled with other components to form aircraft206.

In phase of manufacturing210for aircraft206, fuel tank212in fuel tanks208is a physical structure in which fuel is carried in interior218of the fuel tank212.

In this example, optical data concentrator220is located outside of fuel tank212and optical sensors222are located in interior218of fuel tank212for fuel tank system204. Optical data concentrator220and optical sensors222are connected to each other by optical fibers224. These optical fibers can be bundled in a harness.

In the illustrative example, optical sensors222can detect a number of different parameters for fuel tank212. For example, optical sensors222can detect at least one of temperature, capacitance, fuel density, fuel level, or other suitable parameters.

In this illustrative example, aircraft206is in phase of manufacturing210in which aircraft206can be a partially assembled aircraft. Components for fuel tank system204may not be fully assembled and connected to other portions of aircraft206. For example, fuel tank system204may not be connected to avionics for aircraft206.

As depicted, fuel tank system analyzer232enables testing fuel tank system204prior to fuel tank system204being connected to the avionics for aircraft206. For example, fuel tank system analyzer232can operate to test optical sensors222in interior218of fuel tank212prior to optical data concentrator220being connected to the avionics for aircraft206.

This illustrative example, fuel tank system analyzer232comprises a number of different components. As depicted, fuel tank system analyzer232comprises computer system234and power supply236.

Computer system234is a physical hardware system and includes one or more data processing systems. When more than one data processing system is present in computer system234, those data processing systems are in communication with each other using a communications medium. The communications medium can be a network. The data processing systems can be selected from at least one of a computer, a server computer, desktop computer, a tablet computer, a mobile phone, smart glasses, or some other suitable data processing system.

In this illustrative example, power supply236can take a number of different forms. Power supply236can be one or more electrical devices that supply electrical power228to an electrical load. In this illustrative example, electrical load is optical data concentrator220and electrical power228is delivered in the form of an electric current.

As depicted, power supply236can be selected from at least one of a battery, a generator, an uninterruptible power supply, a switch mode power supply, or some other suitable type of power supply. Electrical power228can be the form of at least one of alternating current or direct current.

In this illustrative example, power supply236is connected to optical data concentrator220. As depicted, power supply236sends electrical power228to optical data concentrator220for fuel tank212for aircraft206such that optical data concentrator220sends optical signals242to optical sensors222inside fuel tank212through optical fibers224connecting optical data concentrator220to optical sensors222. In this illustrative example, electrical power228is sent during phase of manufacturing210of aircraft206.

In this illustrative example, computer system234is in communication with power supply236. Analyzer244in computer system234controls the operation of power supply236to electrical power228to optical data concentrator220. In other illustrative examples, human operators or other mechanisms can be used to control sending of electrical power228by power supply236to optical data concentrator220.

As depicted, computer system234is in communication with optical data concentrator220. In this illustrative example, the communication between computer system234and optical data concentrator220can be provided through at least one of a wired connection, and optical connection, or a wireless connection.

In this illustrative example, analyzer244in computer system234receives test data248from optical data concentrator220. As depicted, test data248is based on optical response signals250received from optical sensors222. These optical response signals are generated in response to optical signals being sent by optical data concentrator220to optical sensors222over optical fibers224.

As depicted, test data248can be sent using a number of different protocols. For example, test data248is sent in data packets using data packets sent over network. In one illustrative example, test data248is sent using controller area network (CAN) packets. CAN packets are generated based on a vehicle bus standard and is a message based protocol. The International Organization for Standards (ISO) has released the following standards for CAN: ISO 118118-1, ISO 118118-2, and ISO 118118-3. Any standard suitable for transmitting test data248from optical data concentrator220to analyzer244in computer system234can be used.

In the illustrative example, test data248includes an identification of the optical sensors and the state of the optical sensors. For example, test data248can be sent by optical data concentrator220using a controller area network bus (CAN) protocol. With this protocol, a message includes an identifier and a corresponding set of data from an optical sensor. A portion of the identifier designates the optical sensor that generated the data in the message.

Analyzer244determines states252for optical sensors222using the test data248. In the illustrative example, states252are selected from at least one of no data, fail, pass, or some other suitable state.

In response to determining states252, analyzer244displays graphical indication254of states252determined for optical sensors222inside fuel tank212in graphical user interface256on display system258. Display system258is a physical hardware system and includes one or more display devices on which graphical user interface256can be displayed. The display devices may include at least one of a light emitting diode (LED) display, a liquid crystal display (LCD), an organic light emitting diode (OLED) display, a computer monitor, a projector, a flat panel display, a heads-up display, or some other suitable device that can output information for the presentation of information. Display system258is configured to display graphical user interface256.

In one illustrative example, displaying of graphical indication254by analyzer244can include displaying fuel tank system map260of sensor locations262showing states252determined for optical sensors222inside fuel tank system in a graphical user interface on a display system.

In other words, the locations of optical sensors are displayed in sensor locations262with states252to provide a visualization of states252of optical sensors222inside fuel tank212. This visualization provides a tool to identify non-conformances268that may be present in fuel tank212.

In one illustrative example, human operator266can view states252displayed on graphical user interface256to determine whether a number of nonconformances268are present for optical sensors222. As used herein, a “number of” when used with reference items means one or more items. For example, a number of nonconformances268is one or more of nonconformances268. The number of nonconformances268can be located in at least one of an optical sensor, an optical fiber, a connector, or some other item inside fuel tank212.

Responsive to a group of optical sensors222having a number of nonconformances268, human operator266can perform action270to resolve the number of nonconformances268in the group of optical sensors222.

Further, states252for optical sensors222also can be stored in data structure264. In this illustrative example, data structure264can be selected from a group comprising a database, a linked list, a flat file, a table, or in some other suitable type of data structure.

With storing states252, historical information can be generated used in analyzing nonconformances for optical sensors inside fuel tank systems. For example, the states can be compared with states determined for optical sensors inside fuel tanks for other aircraft. For example, the comparison of states for optical sensors can be made for left-wing fuel tanks between a group of aircraft. This type of analysis can be used to determine whether changes should be made in the manufacturing process for flow. Further, the analysis can be made to determine whether particular suppliers of optical sensors have more nonconformances than other suppliers.

Analyzer244can be implemented in software, hardware, firmware or a combination thereof. When software is used, the operations performed by analyzer244can be implemented in program code configured to run on hardware, such as a processor unit. When firmware is used, the operations performed by analyzer244can be implemented in program code and data and stored in persistent memory to run on a processor unit. When hardware is employed, the hardware may include circuits that operate to perform the operations in analyzer244.

In the illustrative examples, the hardware may take a form selected from at least one of a circuit system, an integrated circuit, an application specific integrated circuit (ASIC), a programmable logic device, or some other suitable type of hardware configured to perform a number of operations. With a programmable logic device, the device can be configured to perform the number of operations. The device can be reconfigured at a later time or can be permanently configured to perform the number of operations. Programmable logic devices include, for example, a programmable logic array, a programmable array logic, a field programmable logic array, a field programmable gate array, and other suitable hardware devices. Additionally, the processes can be implemented in organic components integrated with inorganic components and can be comprised entirely of organic components excluding a human being. For example, the processes can be implemented as circuits in organic semiconductors.

In one illustrative example, one or more technical solutions are present that overcome technical problems with reducing the time and effort in testing fuel tank systems to determine whether nonconformances are present in optical sensors inside fuel tanks in the fuel tank systems. As a result, one or more technical solutions may provide a technical effect enabling testing fuel tanks at an earlier phase in manufacturing than currently performed.

Computer system234can be configured to perform at least one of the steps, operations, or actions described in the different illustrative examples using software, hardware, firmware or a combination thereof. As a result, computer system234operates as a special purpose computer system in which analyzer244in computer system234enables testing fuel tanks208. More specifically, analyzer244in computer system234can operate to determine states252of optical sensors222when electrical power228is sent to optical data concentrated220. Analyzer244can display states252using graphical indication254which can take the form of fuel tank system map260displayed in graphical user interface256on display system258. In particular, analyzer244transforms computer system234into a special purpose computer system as compared to currently available general computer systems that do not have analyzer244.

The illustration of fuel tank system testing environment200inFIG.2is not meant to imply physical or architectural limitations to the manner in which an illustrative embodiment may be implemented. Other components in addition to or in place of the ones illustrated may be used. Some components may be unnecessary. Also, the blocks are presented to illustrate some functional components. One or more of these blocks may be combined, divided, or combined and divided into different blocks when implemented in an illustrative embodiment.

For example, electrical power228can be sent directly or indirectly from power supply236to optical data concentrator220. For example, power supply236can be connected to optical data concentrator220by a switch or controller. As another example, computer system234can be connected to optical data concentrator220by a switch or controller. In other words, test data248can be sent from optical data concentrator220to computer system234through a switch or controller connecting these two components. In other illustrative examples, these components can be connected directly to each other through cables or wires.

In yet another illustrative example, optical data concentrator220and computer system234can each include wireless transmission capabilities such as Bluetooth circuits or devices. In yet another illustrative example, optical data concentrator220can be located in interior218inside of fuel tank212.

With reference toFIG.3, an illustration of a wing of an aircraft is depicted in accordance with an illustrative embodiment. In this illustrative example, wing300for aircraft302. As depicted, access port304in wing300is shown with the access panel removed. In this view, data concentrator306can be seen on the outside of fuel tank308in wing300.

Turning next toFIG.4, an illustration of another view of a data concentrator is depicted in accordance with an illustrative embodiment. In the illustrative examples, the same reference numeral may be used in more than one figure. This reuse of a reference numeral in different figures represents the same element in the different figures.

As depicted, a view of data concentrator306for fuel tank308fromFIG.3is shown in this figure. As can be seen in this illustrative example, data concentrator306has connector400connected optical fiber cable402and connector404connected to optical fiber cable406. Optical fiber cable402is for Channel A, while optical fiber cable406is for Channel B in which the two channels provide redundancy. Optical fiber cable402is connected to fuel tank connector410and optical fiber cable406is connected to fuel tank connector412. These connectors provide connections to optical fibers inside of fuel tank308. These optical fibers are connected to optical sensors within fuel tank308.

In this illustrative example, data concentrator306also has connector414for Channel A and connector416for Channel B. These two connectors can be connected to a fuel tank system analyzer, such as fuel tank system analyzer232shown in block form inFIG.2. These connections can provide for supplying power to data concentrator306and receiving data from data concentrator306.

With reference toFIGS.5-9illustrations of a graphical user interface for displaying the status of optical tank sensors in a fuel tank is depicted in accordance with an illustrative embodiment. These figures illustrate interface for performing testing and displaying states of optical sensors using a fuel tank system map.

With reference first toFIG.5, an illustration of a graphical user interface for testing a fuel tank in a fuel tank system is depicted in accordance with an illustrative embodiment. In this figure, graphical user interface500is an example of one implementation for graphical user interface256inFIG.2. As depicted, fuel tank system map502is displayed in graphical user interface500. In this example, fuel tank system map502is for a fuel tank system with fuel tanks that includes left tank504, center tank506, and right tank508. In this example, controls510are used to select a fuel tank for testing and to initiate testing of the selected fuel tank. In this illustrative example, right tank502has been selected for testing.

Turning now toFIG.6, an illustration of a graphical user interface showing progress in testing a fuel tank is depicted in accordance with an illustrative embodiment. In this figure, sensor locations are displayed on right tank508. The sensor locations include the sensor location600, sensor location602, sensor location604, sensor location606, sensor location608, sensor location610, sensor location612, sensor location614, sensor location616, sensor location618, sensor location620, sensor location622, sensor location624, sensor location626, and sensor location628. The sensor locations correspond to locations of optical sensors in the right fuel tank. As depicted, the testing can be performed for two channels, Channel A and Channel B. The sensor locations indicate the current channel being tested.

In this illustrative example, two channels are present provide redundancy in case one channel has or develops a nonconformance. In other illustrative examples, other numbers channels can be present such as one, three, or some other number channels.

Additionally, types of sensor status for the optical sensors is displayed in section630. In this illustrative example, the sensor status includes no data632, fail636, and pass638. In this example, all of the sensor locations show the sensor status of no data632.

Sensor status display640is a section in which the status for the optical sensors is displayed. An overall pass fail for fuel tank is displayed in overall pass/fail display642. No indication is shown for an overall pass or fail in overall pass/fail display642in this figure because testing has not yet been performed or completed. The pass or fail is for the current channel being tested.

Messages are displayed in message center644. In this example, the messages show that testing has not started since no data has been received from the data concentrator. In this depicted example, the messages are shown for two channels, Channel A and Channel B, in which testing can be performed for the optical sensors.

As can be seen, the status of the optical sensors is shown as no data for right tank508. In other words, test data has not been received from the optical data concentrator for the optical sensors.

In the illustrative example, information is displayed in graphical user interface500for the active channel. For example, an analyzer automatically switches the display of graphical user interface500to the active channel when a message is received from a different channel. For example, if a Channel B message was received, message center644will display “CH A: Paused”, or if testing is complete for Channel A, message center644displays “CH A: Pass”, or “CH A: Fail”. In this instance, message center644will display “CH B: In Progress”, assuming testing was not completed earlier. In addition, sensor status display640will show the sensor status for the active channel. The active channel is indicated in section641of sensor status display640. In this depicted example, section641displays “Sensor Statuses (CH-A)” and will display “Sensor Statuses (CH-B)” when a message is received from Channel B. Results for both channels can be seen in a summary page once the test is stopped and the summary page is displayed as depicted inFIG.11.

Turning now toFIG.7, an illustration of a graphical user interface showing progress in testing the fuel tank is depicted in accordance with an illustrative embodiment. In this figure, as data is received from the data concentrator, the status of the optical sensors changes to indicate whether the optical sensors are in a pass or fail state. In this example, the optical sensors in sensor location602, sensor location604, sensor location612, sensor location616, sensor location626, and sensor location628are pass. The other sensor locations have not yet responded with sensor data and are displayed as no data.

Overall pass/fail display642does not show an overall pass or fail for the tank. Message center644shows that testing is in progress for Channel A and no testing has started for Channel B.

InFIG.8, an illustration of a graphical user interface showing progress in testing the fuel tank is depicted in accordance with an illustrative embodiment. In this figure, sensor location600, sensor location602, sensor location604, sensor location606, sensor location608, sensor location612, sensor location616, sensor location618, sensor location624, and sensor location626on fuel tank system map502graphically indicate a status as pass. This indication is also made in section640of graphical user interface500. In this example, sensor location610, sensor location620, sensor location622, and sensor location628are shown as no data. Sensor location614is shown as having a fail status. This fail status is also displayed in field RM8 (OCP)800in in section640.

Turning toFIG.9, an illustration of a graphical user interface showing the status of optical sensors in the fuel tank is depicted in accordance with an illustrative embodiment. As the test progresses the sensor locations will show either a pass or fail status. Further, as the test progresses a fail status can change to a pass status or vice versa. In other words, test data can be continually received from the data concentrator over a period of time.

In this figure, all of the optical sensors in the different sensor locations have changed to pass except for sensor location614. This sensor location continues to have a fail state. In this example, the overall pass/fail for the fuel tank being tested is shown as a fail overall pass/fail display642. A fail message is also present in message center644.

With reference now toFIG.10, an illustration of a sensor detail page is depicted in accordance with an illustrative embodiment. In this illustrative example, graphical user interface500displays sensor detail page1000. In this example, sensor detail page1000is displayed in response to selecting sensor location612from the sensor locations on fuel tank system map502.

As depicted, sensor detail page1000shows more detailed information about the optical sensor at sensor location614. As depicted, taskbar1001identifies RM8 (OCP) as the optical sensor that showed fail status inFIG.9.

In this example, right tank508from fuel tank system map502is displayed on sensor detail page1000. This display provides the human operator viewing the graphical user interface to visualize the location of the optical sensor while viewing additional test data. In this example, additional test data is shown in window1002.

As depicted, window1002provides additional information about the testing of the optical sensor. In this example, additional information about state of components shown for part number1004, optical link1006, an optical hardware1008. Part number1004indicates whether the part number for the sensor being tested matches the expected part number for this sensor. If a match is present, part number1004indicates pass as shown in this example. Optical link1006indicates whether the link between the optical sensor and the data concentrator is operating correctly. In this example, optical link1006is shown as fail. The optical sensors can include self-diagnostic processes that allow the optical sensor to determine whether a hardware failure has occurred, which is indicated in optical hardware1008. In this example, optical hardware1008is shown as pass.

Additional sensor data can be displayed in section1010in window1002. This additional sensor data can include, for example, at least one of degradation, fuel density, temperature, capacitance or other suitable information.

With reference next toFIG.11, an illustration of a test summary page is depicted in accordance with an illustrative embodiment. In this illustrative example, test summary page1100is displayed in graphical user interface500. In this illustrative example, test summary page1100shows results for testing right tank508on both channels, Channel A and Channel B.

Turning next toFIG.12, an illustration of a flowchart of a process for testing fuel tank for aircraft is depicted in accordance with an illustrative embodiment. The process inFIG.12can be implemented in hardware, software, or both. When implemented in software, the process can take the form of program code that is run by one of more processor units located in one or more hardware devices in one or more computer systems. For example, the process can be implemented in analyzer244in computer system234inFIG.2.

The process begins by sending electrical power to an optical data concentrator for a fuel tank for the aircraft from a power supply causing the optical data concentrator sends optical signals to optical sensors inside the fuel tank through optical fibers connecting the optical data concentrator to the optical sensors (operation1200). The electrical power is sent during a phase of manufacturing of the aircraft.

The process receives test data from the optical data concentrator, wherein the test data is based on optical response signals received from the optical sensors (operation1202). The process determines states for the optical sensors using the test data (operation1204)

The process displays a graphical indication of the states determined for the optical sensors inside the fuel tank in a graphical user interface on a display system (operation1206). The process terminates thereafter.

With reference toFIG.13, an illustration of a flowchart of a process for displaying a graphical indication of states of optical sensors is depicted in accordance with an illustrative embodiment. The process illustrated inFIG.13is an example of one implementation for operation1206inFIG.12.

The process begins by identifying the optical sensors tested (operation1300). These optical sensors are optical sensors which test data was received when electrical power was sent to a data concentrator. The process selects an optical sensor from the optical sensors tested for processing (operation1302). The process determines an identifier for the optical sensor from the test data (operation1304). In this example, the identifier can be unique identifier or some other identifier assigned to the optical sensor in the fuel tank.

The process identifies the state determined for the optical sensor (operation1306). In operation1306, the states can be selected from at least one of no data, fail, pass, or some other suitable state.

The process selects a graphical indicator for the optical sensor based on the state determined for the optical sensor (operation1308). A graphical indicator can include at least one of an icon, a pictogram, an ideogram, a graphic, an image, text, animation, bolding, a line, an arrow, or other suitable graphic. For example, a circle with a color in which the color selected based on the state of the optical sensor can be used as the graphical indicator. In another illustrative example, different shapes such as a triangle, circle, a square, a diamond, or other shapes can be used based on the state of the optical sensor.

The process identifies a location of the optical sensor from the identifier determined for the optical sensor (operation1310). This identifier for the optical sensor can be used to determine the location of the optical sensor in the fuel tank. For example, the optical sensors installed in the fuel tanks can have their installation locations recorded in a database, table, flat file, or other data structure.

The process assigns the graphical indicator selected to the location on a fuel tank system map corresponding on the location determined for the optical sensor (operation1312). A determination is made as to whether another unprocessed optical sensor is present in the optical sensors identified (operation1314). If another unprocessed optical sensor is present, the process returns to operation1302.

Otherwise, the process displays the fuel tank system map in a graphical user interface on a display system (operation1316). The process terminates thereafter.

With reference next toFIG.14, a more detailed illustration of a flowchart of a process for testing a fuel tank system for aircraft is depicted in accordance with an illustrative embodiment. The process inFIG.14can be implemented in hardware, software, or both. When implemented in software, the process can take the form of program code that is run by one of more processor units located in one or more hardware devices in one or more computer systems. For example, the process can be implemented in analyzer244in computer system234inFIG.2.

The process begins by displaying a fuel tank system map of sensor locations in a graphical user interface on a display system (operation1400). In this illustrative example, the fuel tank system map displays the different fuel tanks present in the fuel tank system. For example, the fuel tank system map may show a left-wing fuel tank, a center fuel tank, and a right wing fuel tank. The computer system and power supply are connected to the data concentrators for these different fuel tanks.

The process receives the user input selecting a fuel tank for testing (operation1402). In this illustrative example, each fuel tank has an associated optical data concentrator and associated optical sensors in which the associated optical data concentrator and the associated optical sensors are connected to each other by associated optical fibers.

The process sending electrical power to an optical data concentrator for the fuel tank selected in the user input from a power supply (operation1404). The electrical power powers the optical data concentrator such that the optical data concentrator sends optical signals to optical sensors inside the fuel tank through optical fibers connecting the optical data concentrator to the optical sensors.

The process receives data from the optical data concentrator (operation1406). The process determines determining states for the optical sensors using the test data (operation1408). The process records the states for the optical sensors (1410). In this illustrative example, the states can be recorded in a data structure such as a database, a table, a flat file, a linked list, or some other suitable type of data structure.

The process displays a graphical indication of the states of the optical sensors on the fuel tank system map of sensor locations displayed in the graphical user interface on the display system (operation1412). The process then returns to operation1402to receive user input selecting a tank for testing.

With reference next toFIG.15, an illustration of a flowchart of a process for testing a fuel tank system for aircraft is depicted in accordance with an illustrative embodiment. The process inFIG.14can be implemented in hardware, software, or both. When implemented in software, the process can take the form of program code that is run by one of more processor units located in one or more hardware devices in one or more computer systems. For example, the process can be implemented in analyzer244in computer system234inFIG.2. In this figure, the different determination operations are performed by the process utilizing user input received from a human operator. Further, the different selections in this process can also be made by user input.

The process begins by determining whether to open a saved test result (operation1500). In operation1500files containing recorded test data from previous tests can also be opened as part of the saved test result. If a saved test result is to be opened, the process selects a saved test result (operation1502). The process displays the saved test result (operation1504). The process then determines whether to open another saved test (operation1505). If another saved test is to be opened, the process returns to operation1502. Otherwise, the process returns to operation1500.

In operation1500, if a saved test result is not to be opened, the process selects an optical phase concentrator for testing (operation1506).

A determination is made as to whether to begin testing (operation1508). In this example, user input can be received to begin the test which is used to make the determination in operation1508. If testing is not to begin, the process returns to operation1500.

With reference again to operation1508, if testing is to begin, the process receives a controller area network bus (CAN) message from the optical data concentrator (operation1509). The process interprets the CAN message (operation1510). In this illustrative example, the interpretation performed in operation1510parses the identifier field of the CAN message to determine what type of data is in the message. If the data from the received CAN message is relevant it is used to determine the status of an optical sensor. For example, the process searches for optical sensor identifiers and the associated test data for those optical sensors. Additionally, timestamps for the test information can also be included.

The process determines whether the CAN message contains sensor data (operation1512). This determination is made using the results of the interpretation in operation1510. For example, each CAN message can include data about the state of a particular aspect of a sensor, such as the optical link, the sensor hardware state, the correct part, and other information. These different pieces of information received in the different CAN messages are used to determine the state of the optical sensor. For example, a CAN message can include a single bit that indicates whether an optical hardware failure has occurred. Another CAN message can include 16 bits of data that holds the part number for the optical sensor. The process looks for the identifiers indicating what type of data is received in the CAN messages. Once a message is detected with test data, the process determines if a pass or failure is present for a particular aspect for that instance. Once all of the test data is collected for an optical sensor, a pass/fail determination for the particular optical sensor is made using the different pieces of information received in the CAN messages from the optical data concentrator.

If the CAN message does not include sensor data, the process returns to operation1508to receive another CAN message. Otherwise, the process updates sensor status data for the optical sensor (operation1514).

The process then displays the status of the optical sensor (operation1516). In operation1516, the display can be a window or other message displayed on a graphical user interface providing the status of the optical sensor. In one illustrative example, when a fuel tank system map is displayed, a graphical user interface for the optical sensor can be updated to indicate the current state of that optical sensor on the fuel tank system map.

The process determines whether to display a sensor detail page (operation1518). Sensor detail page1000inFIG.10is an example of one mentation for the sensor detail page in operation1518. If a sensor detail page is to be displayed, the sensor detail page is displayed on a graphical user interface (operation1520). The process then returns to operation1508to receive another CAN message.

With reference again operation1518, if the sensor detail pages not to be displayed, the process determines whether to stop the test (operation1522). If the test is to be stopped, the process displays a test summary page identifying the test results for all of the tested optical sensors (operation1524). Test summary page1100inFIG.11is an example of one rotation for the test summary page displayed in operation1524

The process then determines whether to whether to save the test summary (operation1526). If the test summary is to be saved, the process saves the test summary to a file (operation1528). In the illustrative example, the test summary can be saved in a desired format such as a comma-separate values (CSV) file, which can be opened by a spreadsheet program. The process terminates thereafter.

With reference again to operation1526, if the test summary is not to be saved, the process terminates. Turning back to operation1522, if the test is not to be stopped, the process returns to operation1509.

The flowcharts and block diagrams in the different depicted embodiments illustrate the architecture, functionality, and operation of some possible implementations of apparatuses and methods in an illustrative embodiment. In this regard, each block in the flowcharts or block diagrams can represent at least one of a module, a segment, a function, or a portion of an operation or step. For example, one or more of the blocks can be implemented as program code, hardware, or a combination of the program code and hardware. When implemented in hardware, the hardware may, for example, take the form of integrated circuits that are manufactured or configured to perform one or more operations in the flowcharts or block diagrams. When implemented as a combination of program code and hardware, the implementation may take the form of firmware. Each block in the flowcharts or the block diagrams may be implemented using special purpose hardware systems that perform the different operations or combinations of special purpose hardware and program code run by the special purpose hardware.

In some alternative implementations of an illustrative embodiment, the function or functions noted in the blocks may occur out of the order noted in the figures. For example, in some cases, two blocks shown in succession may be performed substantially concurrently, or the blocks may sometimes be performed in the reverse order, depending upon the functionality involved. Also, other blocks may be added in addition to the illustrated blocks in a flowchart or block diagram.

For example, in the process illustrated protesting fuel tanks inFIG.14, more than one data concentrator can be present for a fuel tank. In this case, the selection can be made for a portion fuel tank as well as an entire fuel tank when testing optical sensors.

Turning now toFIG.16, an illustration of a block diagram of a data processing system is depicted in accordance with an illustrative embodiment. Data processing system1600can be used to implement laptop computer114inFIG.1and computer system234inFIG.2. In this illustrative example, data processing system1600includes communications framework1602, which provides communications between processor unit1604, memory1606, persistent storage1608, communications unit1610, input/output (I/O) unit1612, and display1614. In this example, communications framework1602takes the form of a bus system.

Processor unit1604serves to execute instructions for software that can be loaded into memory1606. Processor unit1604include one or more processors. For example, processor unit1604can be selected from at least one of a multicore processor, a central processing unit (CPU), a graphics processing unit (GPU), a physics processing unit (PPU), a digital signal processor (DSP), a network processor, or some other suitable type of processor.

Memory1606and persistent storage1608are examples of storage devices1616. A storage device is any piece of hardware that is capable of storing information, such as, for example, without limitation, at least one of data, program code in functional form, or other suitable information either on a temporary basis, a permanent basis, or both on a temporary basis and a permanent basis. Storage devices1616may also be referred to as computer-readable storage devices in these illustrative examples. Memory1606, in these examples, can be, for example, a random-access memory or any other suitable volatile or non-volatile storage device. Persistent storage1608may take various forms, depending on the particular implementation.

For example, persistent storage1608may contain one or more components or devices. For example, persistent storage1608can be a hard drive, a solid-state drive (SSD), a flash memory, a rewritable optical disk, a rewritable magnetic tape, or some combination of the above. The media used by persistent storage1608also can be removable. For example, a removable hard drive can be used for persistent storage1608.

Communications unit1610, in these illustrative examples, provides for communications with other data processing systems or devices. In these illustrative examples, communications unit1610is a network interface card.

Input/output unit1612allows for input and output of data with other devices that can be connected to data processing system1600. For example, input/output unit1612may provide a connection for user input through at least one of a keyboard, a mouse, or some other suitable input device. Further, input/output unit1612may send output to a printer. Display1614provides a mechanism to display information to a user.

Instructions for at least one of the operating system, applications, or programs can be located in storage devices1616, which are in communication with processor unit1604through communications framework1602. The processes of the different embodiments can be performed by processor unit1604using computer-implemented instructions, which may be located in a memory, such as memory1606.

These instructions are referred to as program code, computer usable program code, or computer-readable program code that can be read and executed by a processor in processor unit1604. The program code in the different embodiments can be embodied on different physical or computer-readable storage media, such as memory1606or persistent storage1608.

Program code1618is located in a functional form on computer-readable media1620that is selectively removable and can be loaded onto or transferred to data processing system1600for execution by processor unit1604. Program code1618and computer-readable media1620form computer program product1622in these illustrative examples. In the illustrative example, computer-readable media1620is computer-readable storage media1624.

In these illustrative examples, computer-readable storage media1624is a physical or tangible storage device used to store program code1618rather than a medium that propagates or transmits program code1618.

Alternatively, program code1618can be transferred to data processing system1600using a computer-readable signal media. The computer-readable signal media can be, for example, a propagated data signal containing program code1618. For example, the computer-readable signal media can be at least one of an electromagnetic signal, an optical signal, or any other suitable type of signal. These signals can be transmitted over connections, such as wireless connections, optical fiber cable, coaxial cable, a wire, or any other suitable type of connection.

The different components illustrated for data processing system1600are not meant to provide architectural limitations to the manner in which different embodiments can be implemented. In some illustrative examples, one or more of the components may be incorporated in or otherwise form a portion of, another component. For example, the1606, or portions thereof, may be incorporated in processor unit1604in some illustrative examples. The different illustrative embodiments can be implemented in a data processing system including components in addition to or in place of those illustrated for data processing system1600. Other components shown inFIG.16can be varied from the illustrative examples shown. The different embodiments can be implemented using any hardware device or system capable of running program code1618.

Illustrative embodiments of the disclosure may be described in the context of aircraft manufacturing and service method1700as shown inFIG.17and aircraft1800as shown inFIG.18. Turning first toFIG.17, an illustration of an aircraft manufacturing and service method is depicted in accordance with an illustrative embodiment. During pre-production, aircraft manufacturing and service method1700may include specification and design1702of aircraft1800inFIG.18and material procurement1704.

During production, component and subassembly manufacturing1706and system integration1708of aircraft1800inFIG.18takes place. Thereafter, aircraft1800inFIG.18may go through certification and delivery1710in order to be placed in service1712. While in service1712by a customer, aircraft1800inFIG.18is scheduled for routine maintenance and service1714, which may include modification, reconfiguration, refurbishment, and other maintenance or service.

Each of the processes of aircraft manufacturing and service method1700may be performed or carried out by a system integrator, a third party, an operator, or some combination thereof. In these examples, the operator may be a customer. For the purposes of this description, a system integrator may include, without limitation, any number of aircraft manufacturers and major-system subcontractors; a third party may include, without limitation, any number of vendors, subcontractors, and suppliers; and an operator may be an airline, a leasing company, a military entity, a service organization, and so on.

With reference now toFIG.18, an illustration a block diagram of an aircraft is depicted in which an illustrative embodiment may be implemented. In this example, aircraft1800is produced by aircraft manufacturing and service method1700inFIG.17and may include airframe1802with plurality of systems1804and interior1806. Examples of systems1804include one or more of propulsion system1808, electrical system1810, hydraulic system1812, and environmental system1814. Any number of other systems may be included. Although an aerospace example is shown, different illustrative embodiments may be applied to other industries, such as the automotive industry.

Apparatuses and methods embodied herein may be employed during at least one of the stages of aircraft manufacturing and service method1700inFIG.17.

In one illustrative example, components or subassemblies produced in component and subassembly manufacturing1706inFIG.17may be fabricated or manufactured in a manner similar to components or subassemblies produced while aircraft1800is in service1712inFIG.17. As yet another example, one or more apparatus embodiments, method embodiments, or a combination thereof may be utilized during production stages, such as component and subassembly manufacturing1706and system integration1708inFIG.17. One or more apparatus embodiments, method embodiments, or a combination thereof may be utilized while aircraft1800is in service1712, during maintenance and service1714inFIG.17, or both. The use of a number of the different illustrative embodiments may substantially expedite the assembly of aircraft1800, reduce the cost of aircraft1800, or both expedite the assembly of aircraft1800and reduce the cost of aircraft1800.

Turning now toFIG.19, an illustration of a block diagram of a product management system is depicted in accordance with an illustrative embodiment. Product management system1900is a physical hardware system. In this illustrative example, product management system1900may include at least one of manufacturing system1902or maintenance system1904.

Manufacturing system1902is configured to manufacture products, such as aircraft1800inFIG.18. As depicted, manufacturing system1902includes manufacturing equipment1906. Manufacturing equipment1906includes at least one of fabrication equipment1908or assembly equipment1910.

Fabrication equipment1908is equipment that may be used to fabricate components for parts used to form aircraft1800inFIG.18. For example, fabrication equipment1908may include machines and tools. These machines and tools may be at least one of a drill, a hydraulic press, a furnace, a mold, a composite tape laying machine, a vacuum system, a lathe, or other suitable types of equipment. Fabrication equipment1908may be used to fabricate at least one of metal parts, composite parts, semiconductors, circuits, fasteners, ribs, skin panels, spars, antennas, or other suitable types of parts.

Assembly equipment1910is equipment used to assemble parts to form aircraft1800inFIG.18. In particular, assembly equipment1910may be used to assemble components and parts to form aircraft1800inFIG.18. Assembly equipment1910also may include machines and tools. These machines and tools may be at least one of a robotic arm, a crawler, a faster installation system, a rail-based drilling system, or a robot. Assembly equipment1910may be used to assemble parts such as seats, horizontal stabilizers, wings, engines, engine housings, landing gear systems, and other parts for aircraft1800inFIG.18.

In this illustrative example, maintenance system1904includes maintenance equipment1912. Maintenance equipment1912may include any equipment needed to perform maintenance on aircraft1800inFIG.18. Maintenance equipment1912may include tools for performing different operations on parts on aircraft1800inFIG.18. These operations may include at least one of disassembling parts, refurbishing parts, inspecting parts, reworking parts, manufacturing replacement parts, or other operations for performing maintenance on aircraft1800inFIG.18. These operations may be for routine maintenance, inspections, upgrades, refurbishment, or other types of maintenance operations.

In the illustrative example, maintenance equipment1912may include ultrasonic inspection devices, x-ray imaging systems, vision systems, drills, crawlers, and other suitable device. In some cases, maintenance equipment1912may include fabrication equipment1908, assembly equipment1910, or both to produce and assemble parts that may be needed for maintenance.

Product management system1900also includes control system1914. Control system1914is a hardware system and may also include software or other types of components. Control system1914is configured to control the operation of at least one of manufacturing system1902or maintenance system1904. In particular, control system1914may control the operation of at least one of fabrication equipment1908, assembly equipment1910, or maintenance equipment1912.

The hardware in control system1914may be implemented using hardware that may include computers, circuits, networks, and other types of equipment. The control may take the form of direct control of manufacturing equipment1906. For example, robots, computer-controlled machines, and other equipment may be controlled by control system1914. In other illustrative examples, control system1914may manage operations performed by human operators1916in manufacturing or performing maintenance on aircraft1800. For example, control system1914may assign tasks, provide instructions, display models, or perform other operations to manage operations performed by human operators1916.

In these illustrative examples, computer system234with analyzer244can be implemented in control system1914in which states of optical sensors in fuel tanks determined by analyzer244can be utilized to manage at least one of the manufacturing or maintenance of aircraft1800inFIG.18. For example, an identification of nonconformances in the fuel tank can be displayed on a graphical user interface. Additionally, the identification of nonconformances based on the state of optical sensors can also be used by scheduling components in control system1914generate work orders used to manage operations performed by human operators1916to resolve nonconformances that may be detected.

In the different illustrative examples, human operators1916may operate or interact with at least one of manufacturing equipment1906, maintenance equipment1912, or control system1914. This interaction may be performed to manufacture aircraft1800inFIG.18.

Of course, product management system1900may be configured to manage other products other than aircraft1800inFIG.18. Although product management system1900has been described with respect to manufacturing in the aerospace industry, product management system1900may be configured to manage products for other industries. For example, product management system1900can be configured to manufacture products for the automotive industry as well as any other suitable industries.

Thus, the illustrative embodiments provide a method, apparatus, and system for testing fuel tank systems for aircraft. In one illustrative example, electrical power is sent to an optical data concentrator for a fuel tank for the aircraft from a power supply such that the optical data concentrator sends optical signals to optical sensors inside the fuel tank through optical fibers connecting the optical data concentrator to the optical sensors. The electrical power is sent during a phase of manufacturing of the aircraft. Test data is received from the optical data concentrator by a computer system. The test data is based on optical response signals received from the optical sensors. A determination of states for the optical sensors is made by the computer system using the test data. A graphical indication of the states determined for the optical sensors inside the fuel tank is displayed by the computer system in a graphical user interface on a display system.

One or more illustrative examples provide a technical solution with a technical effect in which a fuel tank system analyzer can test a fuel tank in an aircraft structure prior to aircraft structure being connected avionics or other electrical aircraft systems. One or more illustrative examples provide a technical solution in which a technical effect reduces the time and effort needed to inspect, troubleshoot, and repair the nonconformances in a fuel tank by performing the testing at earlier ages of manufacturing as compared to current techniques. Further, these techniques can also be applied to testing fuel tanks in which maintenance such as routine maintenance, refurbishment, upgrades, or other is performed.

The description of the different illustrative embodiments has been presented for purposes of illustration and description and is not intended to be exhaustive or limited to the embodiments in the form disclosed. The different illustrative examples describe components that perform actions or operations. In an illustrative embodiment, a component may be configured to perform the action or operation described. For example, the component may have a configuration or design for a structure that provides the component an ability to perform the action or operation that is described in the illustrative examples as being performed by the component. As result, one or more illustrative examples can be used to test fuel tanks in a manner that reduces disruption to the manufacturing flow of an aircraft with respect to the time and effort needed to troubleshoot and resolve nonconformances.

Many modifications and variations will be apparent to those of ordinary skill in the art. Further, different illustrative embodiments may provide different features as compared to other desirable embodiments. The embodiment or embodiments selected are chosen and described in order to best explain the principles of the embodiments, the practical application, and to enable others of ordinary skill in the art to understand the disclosure for various embodiments with various modifications as are suited to the particular use contemplated.