The Challenge: Creating a new test suite for BAE Systems to efficiently characterise RF [RF: Radio Frequency] cables within major units of the Eurofighter aircraft.

The Solution: Using the PXI/CompactPCI platform and National Instruments LabVIEW software to design a simplified test system that increases productivity by facilitating more flexible testing. [PXI: PCI eXtensions for Instrumentation, PCI: Peripheral Component Interconnect]

The Eurofighter Typhoon is a state-of-the-art combat aircraft developed in cooperation with Germany, Italy, Spain and the UK. This sophisticated, next-generation fighter has been engineered to meet military needs for generations to come. BAE Systems, a leader in these types of joint programs, has been working with other leading aerospace companies to make sure the Eurofighter Typhoon is unparalleled in design and performance.

Developing an Effective Test Suite for RF Cables
The company needed a new test suite for more efficient RF cable characterisation within major units of the aircraft. These units, produced at BAE Systems Samlesbury, have high-performance coaxial cables that require testing prior to delivery to ensure that no

damage has occurred during installation. Every cable has different operating frequency, cable length and routing characteristics, and each of these characteristics impacts performance.

The original method required specialist engineers to conduct testing, but this was expensive and it limited testing to a small window of time. However, a system in which shop operators conducted the tests would mean more flexibility for production and the ability to conduct 24-hour-a-day, seven-day-a-week testing.

BAE Systems consulted with us at TBG Solutions to define the parameters needed for a more effective test system. The operators, who may have little RF engineering knowledge, would need to conduct all testing requirements for the three product areas. The system would have to automate the test equipment setup routines and test each product fully, including individually testing each cable as required. We needed to develop a system that also would implement phase matching and BAE Systems could easily update for growth. Finally, we wanted the system to use the existing Anritsu scalar analyser, and we needed the equipment to meet strict security requirements for use with potentially sensitive information.