Transforming Aerospace & Defence with State-of-the Art Test Systems

Exponential growth in Aerospace & Defence sector demands testing solutions for entire project life cycle. Captronic Systems with its in-depth domain expertise over two decades can provide you the optimal testing solution for conception, design, development, validation, production and maintenance of your project.

What Makes Us Different?

500+ Successful Projects

In-depth understanding of Aerospace & Defence Testing Requirements

Superlative Quality Systems

Leveraging Skilled Workforce

System Categories

Captronic Systems has delivered more than 500 successful projects to the Aerospace and Defence Sector over the span of20 years! We have worked with almost all the major Defence Research and Development Organisations – DRDOs, PSU’s like Hindustan Aeronautics Limited (HAL), Bharat Electronics Limited and several private A&D industries PAN India. The core team consists of A&D experts who provide deep insights into the evolving sector requirements.

Below are some of the projects which showcase the wide nature of projects that we have handled.

Automated Test Equipment

Control Systems

Data Acquisition Systems

Hardware in Loop Simulation

Automated Test Equipment (ATE)

Printed Circuit Boards - Generic ATE

The PCB Automated Test Equipment (ATE) was developed to test the different Printable Circuit Boards, PCB’s. The system is capable of conducting automated tests, troubleshooting the defects while testing and generating test reports.

The system automates the measurements using a combination of National Instruments PXI modular instrumentation architecture and traditional programmable instruments from Keysights, Keithley, Tektronix. It achieved faster testing cycles than the traditional approach.


Break Management System (RTS BHEEM – EU) ATE

The Break Management System (BMS) is capable of carrying out full hardware & software functionality tests of Brake Control, Hydraulics, Engine and Electrical Monitoring – Electronic Unit with simulated system input signals in manual modes & fully automated testing mode.

The system uses NI PXI platform which has a Real Time Operating System which simulates various input and output signals to and from BHEEM-EU, achieving a complete functionality testing of Electronic Unit. It has been successfully delivered to DRDO and HAL.


Digital Flight Control Computer ATE

The DFCC ATE performs memory tests, interrupt tests and external interface tests of Digital Module(LRU). The ATE consists of NI PXI chassis with I/O modules, Programmable Power Supplies and Real Time controller. ATE confirms that Flash, SRAM and NVRAM are working properly. 

Interrupt tests validate interrupt priorities and interrupt service routine. The External interface test is to validate Digital module external interfaces like D/A and A/D Interface, CCDL Interface, MIL-1553, Spin Motor Rate Detector (SMRD) Interface, RS-422 Interface, Discrete I/O Interface, ethernet etc.


More Projects under Aerospace & Defence ATE.

Portable ATE for the Digital Engine Control Unit (ECU)

A Full Authority Digital Engine (or Electronics) Control (FADEC) is a system consisting of a digital computer, called an “electronic engine controller” (EEC) or “engine control unit” (ECU), and its related accessories that control all aspects of aircraft engine performance.

ATE tests the functionality of the twin lane FADEC unit. It consists of a PXI chassis loader with I/O Modules, Simulator Modules (RTD simulator, LVDT simulator, Thermocouple simulator) and connectivity modules (Matrix switches and SPST switches) and interlink card to extend PXI bus.


Radio Frequency Integration Test Rig - Rustom II

Rustom – II is a medium altitude, long endurance unmanned aerial vehicle UAV. The test system performs the test and validates the functionality of individual as well as integrated chain Line Replacement Units (LRUs) of Uplink and Downlink of a communication Link.

National Instruments hardware & software tools are primarily used. Telemetry and channel simulator is one of the major components of the system along with the GPS interface simulator system. The switching of RF signals between desired LRUs and simulators done by the RF switch matrix.


ATE for T-90 Battle Tank CU & ADB

The T90 ALG Automated Test equipment (ATE) is capable of performing tests of two types of UUT’s: Control Unit and the Additional Distribution Box. Different output voltages and ground produced at different output terminals of UUT will be measured and validated by the system.  

This ATE is based on Ni ‘s PXI platform. The application software for the ATE was developed using NI LabVIEW and NI Test Stand. Users can configure and run various test sequences in dual (manual and auto) operations mode. Features like health checks are provided for preventive maintenance.


ATE for Testing LRU Modules and PCBs

The above testing system was developed for testing Printed Circuit Boards and Line Replaceable Units for Akash Army Launcher. The system is capable of manual and automated testing, troubleshooting the defects while testing and generating test reports.

Based on the NI PXI form factor and other traditional programmable instruments from TDK-Lambda, Chroma etc. the system is scalable and modular in nature. It has been programmed through LabVIEW, Teststand and MySQL.


Control Systems

Actuator Test System

This control system is built to control three systems: Fan Variable Geometry Actuation System, Compressor Variable Geometry Actuation System and Fuel Control Test system. The system also acquires data from various sensors such as pressure and flow.

The system can perform two tests namely, System Calibration and Cyclic test. System calibration is a closed loop test. The actuator system and the fuel control system are controlled by the software PID controllers which take user demand and position feedback values as the inputs.


Drive by Wire System for BMP-II Tank

A Drive by Wire or DBW is a control system that is used to control and navigate the UAV from a base vehicle via wired communication links through wireless links. Before making the vehicle RF comm driven it is first controlled through wired communication.

Captronic Systems has successfully implemented Drive by Wire Module to control and navigate a remote BMP II vehicle from base BMP vehicle up to a specified speed through controlling different actuators and associated electronic control units.


High Speed Image Processing Module

Jitter is the undesired fluctuation in the pointing of a laser beam due to environment or structural interactions it reduces the intensity of the beam at the target. It is critically important to avoid fluctuations and drifts in laser beam alignment.

Our system captures the image of LASER spot from the target plane & processes its position on the NI FPGA Module. After processing the image, the system generates the corresponding analog output to correct the position of the LASER spot in XY Planes.


More Projects under Aerospace & Defence CS.

Nozzle Control System

The Nozzle Control System is built for testing Integrated Nozzle Actuation System, Integrated Nozzle Pumping System, Nozzle Loading Simulator, Thrust Vectoring Nozzle and Independent Servo Systems of an aircraft.

Based on the NI PXI platform, Real time controller is used along with different I/O modules and LabVIEW for programming. Various automated test sequences can be run and real time digital and analog data can be monitored and logged for offline analysis.


Tower Testing System

Tower testing & Research Station TTRS of CSIR-Structural Engineering Research Center is a nodal test center for evaluation of structural strength of the HT Tower used in power transmission.  

40 Channel Real Time Digital Control System (RTDCS-40) was implemented in this project  which was used for load control of the rams during commercial tower tests at SERC-TTRS. Existing infrastructure was seamlessly integrated with this control system.


Data Acquisition Systems

Piston Engine Data Acquisition and Control System

CSPL has developed a portable CDAQ based control system that allows users to monitor and record Rustom UAV’s piston engine parameters. The system is capable of testing and validating the performance of the Piston Engine.

The NI based solution with the CDAQ and the corresponding modules allow the sensors and the actuator to acquire data and control. The system is capable of carrying control operation and data acquisition in auto and manual modes.


DAS for FCS Sensors

 The Data Acquisition System for Flight Control System sensors is basically an acquisition system which acquires, monitors, the data pertaining to different sensors of LRU’s (ASA, RSA, AOA, TAT). 

The system is capable of testing and acquiring data from LRU’s by conducting two tests. “Self-Test on Sensors” and “Pre-Installation Test”. The system is based on the National Instruments modular and scalable PXI platform.


Air Data & Digital Flight Control Computer DAS

This Analog and Discrete Data Acquisition system is capable of acquiring signals in parallel and recording the data in real time. The system consists of Multifunction DAQ cards and DIO cards.  

The system can be configured to work in standalone mode and in integrated mode where it is connected with the Line Replaceable Units (LRUs). The System is capable of generating customized test reports based on the LRU connected.


More Projects under Aerospace & Defence DAS.

DAS for FCS Sensors

 The Data Acquisition System for Flight Control System sensors is basically an acquisition system which acquires, monitors, the data pertaining to different sensors of LRU’s (ASA, RSA, AOA, TAT). 

The system is capable of testing and acquiring data from LRU’s by conducting two tests. “Self-Test on Sensors” and “Pre-Installation Test”. The system is based on the National Instruments modular and scalable PXI platform.


Microgravity Drop Tower Test System

The Microgravity Drop Tower Test system was designed to observe the flame at the microgravity condition, the test is conducted in a drop capsule at 38 m Height, During the drop the inner capsule would experience microgravity during the course of falling.

The system conducts an automated execution of the drop sequence during the experiment and performs data acquisition from different sensors. The system is capable of logging data in real time and transmitting it live to the HOST PC.


Remote Bridge Monitoring System

The above system is designed to monitor and assess the structural integrity and condition of bridges. The system uses different types of sensors to monitor different parameters on the bridges.

The system architecture contains a remote PXI chassis which is the primary Data Acquisition system and is installed on remote sites. A centralized control room is situated at CSIR SERC, using a different mode of communication.


Slam Chop System

The slam chop system is designed to acquire and monitor data from different types of sensors. Physical parameters like Pressure, Temperature and Speed are continuously acquired in parallel loop architecture.

UDP communication host client architecture is implemented in this project. The slam chop system uses PXI express chassis, controller and I/O modules. Specialized scalable Data Acquisition and Monitoring Software (DAMS) DAMS software is implemented in LabVIEW.


Hardware In Loop Simulation (HILS)

Advanced Medium Combat Aircraft (AMCA) System Simulation Facility

The above system is basically a facility of AMCA, an engineer-in-loop real time system simulation facility where an engineer can fly the AMCA using Table Top generic pilot controls & projected imagery.

It does function of evaluating and verifying the control law’s using simulated avionics and flight dynamics. The SSF system simulates these subsystems. Flight Dynamics Simulator, Sensor Simulator, Engine Simulator, Actuator Simulator, Flight Control Computer Simulator, Pilot Controls and Cockpit Simulator.


FADEC Simulator System

A full authority digital engine (or electronics) control (FADEC) simulator system is used to test the Twin Channel FADEC Control unit before it can be further integrated with other subsystems of ECU.

The system processes the sensor signals and generates output drives to control main and after burner fuel flows, compressor and fan blade angles, nozzle actuator and anti – ice valve positions.


Flight Dynamic Simulator

Flight Dynamic Simulator (FDS) is a real time dynamic simulator is a state-of-the-art technology to run Fortran/C aircraft dynamic model and to interface I/O’s of cockpit and Engineering Test Station to acquire the actuator position, pilot controls and simulates the sensor output to facilitate the flight simulation.

This PXI based FDS is designed for Iron Bird Aircraft. The system simulates the sensor signals for the study of the realistic dynamic behavior of an aircraft. The System is aimed to be used for the evaluation of the Light Combat Aircraft (LCA).


System Gallery

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