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Multi-Channel Control Systems

The Model ECI-SFT 16.PP57.01 from Electro Communications Research Institute (ECI) is one of the most proven digital servo-controllers available for full-scale structural testing under both static and cyclic loading conditions. Full-scale strength and fatigue life evaluation for airworthiness certification of well-known transport and military aircraft including the Tu-204 passenger liner, Mig-29, Su-27 and Su-30 were performed on test rigs controlled by ECI-SFT controllers. More recently, the system was chosen for full-scale structural testing for endurance of the Sukhoi-Boeing Russian Super Jet program.

The quality and reliability of the ECI-SFT16.PP57.01 are ensured by exclusive use of B&R electronic hardware modules which serve as a global industry standard. The system and application software supplied with the ECI-SFT 16.PP57.01 reflect many years of experience of the Siberian Aircraft Research Institute (SibNIA). ECI is the prime contractor for full-scale test controls at SibNIA. The vast structural test hardware base at SibNIA with over 15,000 sq. meters of test floor space and over a thousand servo-actuators served as the proving grounds for the ECI-SFT16.PP57.01.

Most full-scale structural tests on airframes require more than 16 channels of control. The Model ECI-SFT16.PP57.01 controller is engineered for operation in a real-time high-speed digital network. There is practically no limit on the No. of channels achievable using multiple Model ECI- SFT16.PP57.01controllers, connected to a single Master Host Computer. Up to 256 Model ECI-SFT16.PP57.01controllers can be connected to a single hub limited to 4096 control channels. B&R modules are engineered for operating in a networked environment with a wide choice of communication protocols, all of which are supported by application software drivers

Features :

  • 16, 32, 48, 96, 128, 256, 384, 512 Channels control systems
  • Multi-channel static and cyclic (fatigue) testing of airframe structures with up to 16 actuators or other control units such as fuel tank / cockpit / cabin pressure, temperature, etc
  • The control Nodes are Modular in design, allows easy upgradability to more No. of channels. Capable of operating independently and as group.
  • Connection of Dual Strain Bridge and one LVDT transducers for each of 16 control channels. Strain bridge pressure transducers may be connected for pressure control. Total 48 feedback channels. Dual strain bridge provision is used by application software to track load the parallel readouts and to suspend testing in the event of unacceptable deviation as an indication of fault.
  • Exercise of predefined test assignments including stepped tightly synchronized static loading, pre-programmed pseudo-random flight-by-flight load sequences and arbitrary load levels designated during operator control using pre-selected feedback channels including Force, Actuator Displacement, Pressure, temperature, etc.
  • Enforcement of upper and lower limits on feedback channels as well as limits on loop error, with option of HOLD, STOP/UNLOAD and TRIP.
  • Internal logical assignment of feedback channels to individual control channels
  • Independent drive control to disable/enable, any single, group of or all actuators
  • 16 channels of servo output with current rating 100 mA to suit Moog 2-stage servo-valves.
  • Data acquisition from all feedback, control and servo-output channels (total 96 analog channels) plus digital status of all 16 control channels.
  • Two channels of analog outputs for recording / display on external units. Any two of the acquired data channels (96) can be directed as either of these two outputs.
  • Grouping of control channels into independent test stations for use of Controller as host controller to multiple independent tests, each with its own set of control and feedback channels and with own sequence of testing, safety interlocks and drive control.


Features :

  • Capable of creating test setup in Static as well as Fatigue modes and executing them
  • Storage of test setup files and retrieves it for future use of similar test sequences
  • Waveform generator includes waveforms viz. Sine, Triangle, Square and ramp
  • Auto zero and Auto Calibration of each channel. Calibration details can be digitally stored.
  • User settable Electronic safety alarms (limits) to shutdown the power pack / individual or group of actuators in the event of alarm (ex. Max. Load, Min. Load,) hits.
  • Data storage of each test conducted
  • Data acquisition rates up to 5 kHz per channel. User allowed to change the rates as per the test requirements
  • Tuning of all Servo channels with auto/user defined PID adjustments
  • Hydraulics Start / Stop with Low/High pressure control
  • Channels can be grouped to user choice or can be used independently.
  • Status display of test under progress with running segment No, elapsed segments etc.
  • Live Data Display of all channels in Analog and Digital forms
  • Log sheet for monitoring test sequences and events of each channel viz., start, stop, hold, limits, low pressure, high pressure, fault conditions, errors, alarms, etc.
  • Status display of all channels listing the alarms and reaction of the system
  • Each channel or a group of channels can be designated with the name of component or aircraft part under test
  • Graphical display of Set point, Feedback and servo signal of all channels
  • Histogram (bar graph) display of all feedback channels
  • Option to switch data recording ON/OFF during a test sequence
  • Report generation after the test is completed

Applications :

  • Static and Fatigue load simulation on flight components or full flight
  • Static and fatigue load simulation on structural components or full structures
Parameter Specification
Multi-channel capability
Number of control channels 16
Strain bridge inputs 32
LVDT inputs 16
Logic outputs with 24V drive 16
Servo-valve outputs (Current compatible with Moog 2-stage valves) 16
Analog signal outputs 2
Accuracy and resolution
Maximum command signal frequency 100 Hz
Digital loop update 2 to 5 kHz
Data Acquisition per channel Up to 5kHz
Feedback control accuracy < 1%
Strain bridge conditioner 24 bit
LVDT conditioner 16 bit
Analog and current outputs 16 bit
Control waveforms Sine, Triangle, Square, Ramp, arbitrary
Safety limit interlocks Coarse tolerance on transient, fine tolerance on peak-to-peak, dual strain bridge deviation
Safety limit trigger response Stop, Unload, Switch Off individual, group or all actuators
User interface
Channel-wise histograms of actuator response and transient response graphics on individual channels. Emergency reports and action taken reports. CPU Geode LX800 RAM 128 MB VGA, 640 x 480 Diagonal 5.7" Touch Screen Panel on Controller
Detailed application status and graphics on Master Host Computer. CPU E5200, 2.5 GHz RAM 4 GB HDD 640 GB LCD 1920x1080 Laser printer
Connection of multiple controllers through ETHERNET POWERLINK, or TCP/IP protocol, restricted only by network capability. Spatial separation of individual controllers and controller modules restricted only by network cabling restrictions
Connection of other real-time and non-real-time devices through Ethernet or RS-232, such as 3rd party data acquisition systems, strain gauge data loggers, printers, hand-held wireless operator consoles, etc.
Connection of additional computers on same network for concurrent processing including watchdog functions

About Us

Measure India Corporation (MIC) was founded in the year 2006, based at Hyderabad, India, by well experienced engineers in the field of material testing. It was started with a goal to provide arguably the best possible, yet, affordable solutions for materials and components