Power control system

Electronic systems

Inspection systems

The technological evolution of the production process and the quality requirements in the market has strongly increased the needs for inline control of final products like nonwovens, plastic covering, transparent and coating materials, abrasives, paper and rubber.

In order to meet these Customers’ requirements Electronic Systems proposes different inline web inspection systems able to control 100% of produced material detecting and showing the quality and defects.

Flexin

The Flexin entry level software assure the following real time performance:

• On-line defects detection

• List of defects images

• Defects reel-map

• Defects counters devided by dimensions and type

• Trends

The system is able to detect and classify the defects according to the parameters that have been established. It is possible to enable/disable the visualization by different typologies of defects and/or their dimensional class. The map of the bobbin can be printed out automatically and the relevant data can be sent to the production management system of the factory

SYSTEM ARCHITECTURE

The system comprises a number of CCD cameras, with an integrated PC and Frame Grabber, one or more lights placed on the line and one operator console for visualization and quality control.

The defects are detected in real time and shown on a map which indicates the relevant class and types. It is also possible to include alarms, displays trends and/or counters.

The FLEXIN’s architecture is designed for Windows, it is very adaptable to any industrial requirement and user friendly.

Flexcord

Flexcord  system is a special scanning device, with a X-ray emitter and a linear sensor. For steel cord – rubber production , it it can to monitor continuously monitor the presence of steel cords inside the rubber production for tires.

The high system resolution allows toenables the measurement of the distance between each one cord and the next one, so it can give giving an immediate alarm in case where such distance exceeds the specification.

The performed real-time measurements made  for each scan over the web are the:  number of detected cords;, the average, minimum and maximum of distance and; and the step of cords.

A special measurement can be performed on the edges to  detectto detect the width of rubber outside the first and last cord. This special measurement can be activated achieved on alternate each scanssion or it can be performed continuously continuouslystopping  the head alternatively over the two edges.

The Flexcord system is tuned to work with minimum xrayx-ray emission., it’s controlledIt is engineered not to exceed 37Kv with a maximum current of 1.25mA, while whereas a typical dental  Xrayx-ray device works from 50 to 70Kv with 2 to 8 mA of current.

Flex Feed

Flexfeed system is a calendar feeding control system working with thermographic IR cameras. It  provides stable and reliable information about the amount of material between calendar cylinders. The different IR emissions between the molded plastic and the cylinders provides a clear image of the amount of feeding, no matter the type or color of material being produced.

It is able to work in direct connection with the feeding system to control the amount of feeding as well as its left-middle- right distribution.


Flexfeed includes some useful  additional features like the temperature distribution on the surface of molded plastic that can help to ensure better handling on the first step of film production. The system backs up  continuously a simple AVI file, with one image every 2 seconds, that provides access  to  all monitored production 24hours a day for one year.

Scaneye

Scaneye is a scanning system with one or more cameras that performs inline a detailed online  online detailed analysis  on of a small portion of of a surface., so iIt can perform dimensional measurements onlineinline, moving across the web, withweb with a resolution close tothatto that of  a microscope in laboratory.

Scaneye hasis composed by one camera with a special optic capababiltysolution to get an enlarged image of the web surface. and a It has a lighting unit with high power LEDs that are configured to better enhance the surface viewaspect. Each measurementd feature is compared with a reference grid to producing e a conformity map of all production.

Limitation: The enlarged image needs a very high camera speed;, for this reason it is may beusually difficult to ausepply it Scaneye in productions with speeds faster than 100m/min.

Typical applications: not uniform non-uniform coatings which is not unkform, check analyzing of grit distribution in abrasive productions, embossing checks and such like similar processes.so on.

FlexOut

FLEXOUT – THE LAST STEP FOR A GlOBAL WEB INSPECTION SOlUTION

Our extensive experience using web inspection with Flexin systems has shown that often the defect detection creates a problem, i.e. What to do with detected defects? Thus a web inspection system, like Flexin, is just the first step of a global web inspection solution. Electronic Systems has produced a complementary system called Flexout to finish the job by creating a real web inspection solution.

The Flexout inspection system can be applied every time  a big roll is produced. The roll can then be cut into slits or rewound where defects need to be removed  post production.

A standard solution is to install a labeler so the defect can be marked directly on the web, but this solution requires an operator that continuously checks when the labels are coming and slows down the slitter in advance to find the label position at the  slower speed.

A similar result can be achieved by looking at the defect map saved by the Flexout web inspection system. Electronic Systems has many years of experience working together with slitter operators during Flexin startups.

The experience of Electronic Systems has been included in the Flexout system to make the defect removal process easier and faster by using a statistical approach and dedicated tools.

The Flexout system will automatically stop the slitter at the defect position. By using statistics from day to day operations, it learns how to find the defect positions in a more accurate, safe, and timely way.
Automation

ELECTRICAL ENGINEERING

Electrical engineering is carried out with CAD systems:

• Spac

• Eplan P8

Documents can be supplied in .PDF, .DXF and .DWG format. They consist of:

• Single-wire electrical diagram

• Functional diagram

• Cable lists

• Parts list

• Equipment layout

• Certificates of conformity

• Test certificates

• User manual

• Data sheet of components

With the purpose of offering a “turn key” solution, our company also supplies the plan of the systems on board the machine and offers a work supervision service on site.

Electronic Systems has been working in the automation industry since the very beginning and offers a complete range of products and services suitable for any issue connected to production processes.

We mainly realize the following process typologies:

• Production plants for plastic materials (calendering lines, Cast film, Blown film, Breathable, Coating, and Biax films)

• Production lines for rubber (calendering lines, extrusion lines, RollerHead, Innerliner, mixers)

• Coating and lamination plants

• Plants for fabric treatment

• Cable production lines

Electric engineering, software development and equipment manufacturing are totally carried out in our company. All the equipment is tested in compliance with current regulations in force. Special attention is given to safety circuits whose components and circuits belong to the safety class declared by the machine producer. (Electronic Systems has already enforced the new ISO 13849-1 standard and is at your disposal for supplying documents about its own “performance level”).

Complete plant

AUTOMATION FOR INDUSTRIAL PLANTS

All process variables can be used for data collection and tracking systems. Electronic Systems also provides a teleservice system

and maintenance staff training courses.

SOFTWARE

Electronic Systems uses control systems based on PLCs produced by world leading manufacturers among whom:

• Siemens

• Rockwell (of whom we are “Recognized Systems Integrator”)

• General Electric

• Schneider

• Omron

Signal shift and acquisition use the most widespread field buses such as:

• Profibus

• Profinet

• ControlNet

• DeviceNet

• Modbus

• Ethernet/IP

The machine user interface is built using local operator panels and SCADA systems based on market leading packages:

• Siemens WinCC

• Intouch

• RSView 32

• GE Cimplicity

Rework

SYSTEM DESCRIPTION – POSSIBlE APPLICATIONS

Production line, commonly denominated as “Rework Line” design to process to rubber sheet shape after filter it (filter is a process option), rework tire components like treads and sidewalls, by means of combine control utilization of mills, straining by gear pump and

palletizer equipment (batch off).

• Sheeting process: rework tire components are feed by means of a conveyor into a cracker mill and after that automatically transported to a homogenizing mill, and consequently to a feeding mill, finalizing the process in a sheeter mill. After that is cool down and palletizer in a batch off equipment.

• Filter process (1st option): same as sheeting process, but before material be transferred to the sheeter mill is filtered by means of a gear pump and a strainer head.

• Filter process (2nd option): Case material is already in a sheet format and is necessary only to filter. Process is starting by means of a batch feeder conveyor directly in the homogenizing mill. After that same process as steps before.

PROJECT MANAGEMENT CAPABILITIES

• Layout can be work out according the available space using 3D design tools

• Automation & control using possible different solutions as Siemens or Rockwell

• Turnkey installation possibility or supervision base

ADVANTAGES OF A REWORK LINE

• Prepared to strain final batch compound with a max output of  2,5 t/h

• Prevent strange material coming from the “workoff” to appear in compounds, green and cured tires

• Sheet the Sidewall and Innerliner work-off, increasing the mixing capacity by not using that time in a mixer equipment

• Recover for normal use not approved compounds with strange material or cured rubber (scorch)

• Space restrictions in the mixing room. Sheeting process of “workoff” compounds (tire treads and sidewalls) creates conditions to storage in automatic • • warehouse (high bay storage) or standard shelving

• Sidewall output increasing by straining critical compounds offline

• For plants using cap strip process machines, increasing of the output by filtering the material in advance and offline

• Clean batches coming from mixing line with scorch, reducing scrap

• Low maintenance equipment, due the “friendly” maintenance solutions developed

• Line easy to operate.

Mills

Our mills stand out due to their strong steel casting construction, compliance with the current Eu standards, and their fully integrated capability of automation, in the several different market platforms, as Siemens and Rockwell.

Depending on the final application we can customize the mill to you own application, below some im-

portant features:

• Range of specifications: Ø 360mm – Ø 810 mm and roll width from 40” to 84”

• Construction of mill rolls: drilled roll, bored roll, grooved roll, made of special chilled cast iron with long service life

• Methods of adjusting roll nip: manually, electrically, hydraulically

• Drives: AC, DC, hydraulic

• Prepared to be tempeture controlled in the roll, by TCU (temperature control units)

• Compliance with the current EU standards

• Possible to be equipped with additional customer requests as: cutting devices, stock blender, different drive options, ie, individual roll speed or constan.

Complete revamping

The decision to revamp equipments has as background the following reasons and arguments:

• Spare parts for installed equipment have become obsolete or very expensive

• Equipment isn’t complain with safety and CE normative

• Maintenance becomes expensive and production down time increases

• Production time cannot meet market demands or new product recipes are too complex for old equipment

• When companies are relocating equipment from other manufacturing locations requiring installation with a current system; revamping is a solution.

Renovating and reconstructing from mechanical and automation point of view equipment from the rubber and plastic industry, with special focus in:

• Extruder Lines

• Calender Line

• Innerliner lines

• Rework Lines

• Mills

• Other special applications under request.

Turn key plant

Turnkey experienced capabilities areas in the rubber and plastic field:

• Project survey or OEM description interpretation

• Layout design (supported by 3D tools)

• Project Gantt definition

• Engineering/Equipment selection

• Software design (Siemens, Rockwell, Beckoff platforms or others under request)

• HMI/SCADA visualization system with or without DB integration

• On site installation (mechanical and electrical)

• Project commissioning

• Training

• CE declaration.

ELECTRONIC SYSTEMS is experienced in assisting companies with turnkey projects, from OEM projects to revamping projects we can work the project from the survey phase to the last phase, ie, equipment training and machine handover.

We can take the full responsibility of the project, following the client specification using our internal solutions and partners or we are also prepared to work with client customized partners.

Electronic control systems

Electronic systems

An Electronic System is a physical interconnection of components, or parts, that gathers various amounts of information together with the aid of input devices such as sensors, responds in some way to this information and then uses electrical energy in the form of an output action to control a physical process or perform some type of mathematical operation on the signal.

But electronic control systems can also be regarded as a process that transforms one signal into another so as to give the desired system response. Then we can say that a simple electronic system consists of an input, a process, and an output with the input variable to the system and the output variable from the system both being signals.

There are many ways to represent a system, for example: mathematically, descriptively, pictorially or schematically. Electronic systems are generally represented schematically as a series of interconnected blocks and signals with each block having its own set of inputs and outputs.

As a result, even the most complex of Electronic Control Systems can be represented by a combination of simple blocks, with each block containing or representing an individual component or complete sub-system. The representing of an electronic system or process control system as a number of interconnected blocks or boxes is known commonly as “block-diagram representation”.

Block Diagram Representation of a Simple Electronic System

Electronic Systems have both inputs and outputs with the output or outputs being produced by processing the inputs. Also, the input signal(s) may cause the process to change or may itself cause the operation of the system to change. Therefore the input(s) to a system is the “cause” of the change, while the resulting action that occurs on the systems output due to this cause being present is called the “effect”, with the effect being a consequence of the cause.

In other words, an electronic system can be classed as “causal” in nature as there is a direct relationship between its input and its output. Electronic systems analysis and process control theory are generally based upon this Cause and Effect analysis.

So for example in an audio system, a microphone (input device) causes sound waves to be converted into electrical signals for the amplifier to amplify (a process), and a loudspeaker (output device) produces sound waves as an effect of being driven by the amplifiers electrical signals.

But an electronic system need not be a simple or single operation. It can also be an interconnection of several sub-systems all working together within the same overall system.

Our audio system could for example, involve the connection of a CD player, or a DVD player, an MP3 player, or a radio receiver all being multiple inputs to the same amplifier which in turn drives one or more sets of stereo or home theatre type surround loudspeakers.

But an electronic system can not just be a collection of inputs and outputs, it must “do something”, even if it is just to monitor a switch or to turn “ON” a light. We know that sensors are input devices that detect or turn real world measurements into electronic signals which can then be processed. These electrical signals can be in the form of either voltages or currents within a circuit. The opposite or output device is called an actuator, that converts the processed signal into some operation or action, usually in the form of mechanical movement.

Types of Electronic System

Electronic systems operate on either continuous-time (CT) signals or discrete-time (DT) signals. A continuous-time system is one in which the input signals are defined along a continuum of time, such as an analogue signal which “continues” over time producing a continuous-time signal.

But a continuous-time signal can also vary in magnitude or be periodic in nature with a time period T. As a result, continuous-time electronic systems tend to be purely analogue systems producing a linear operation with both their input and output signals referenced over a set period of time.

For example, the temperature of a room can be classed as a continuous time signal which can be measured between two values or set points, for example from cold to hot or from Monday to Friday. We can represent a continuous-time signal by using the independent variable for time t, and where x(t) represents the input signal and y(t) represents the output signal over a period of time t.

Generally, most of the signals present in the physical world which we can use tend to be continuous-time signals. For example, voltage, current, temperature, pressure, velocity, etc.

On the other hand, a discrete-time system is one in which the input signals are not continuous but a sequence or a series of signal values defined in “discrete” points of time. This results in a discrete-time output generally represented as a sequence of values or numbers.

Generally a discrete signal is specified only at discrete intervals, values or equally spaced points in time. So for example, the temperature of a room measured at 1pm, at 2pm, at 3pm and again at 4pm without regards for the actual room temperature in between these points at say, 1:30pm or at 2:45pm.

However, a continuous-time signal, x(t) can be represented as a discrete set of signals only at discrete intervals or “moments in time”. Discrete signals are not measured versus time, but instead are plotted at discrete time intervals, where n is the sampling interval. As a result discrete-time signals are usually denoted as x(n) representing the input and y(n) representing the output.

Then we can represent the input and output signals of a system as x and y respectively with the signal, or signals themselves being represented by the variable, t, which usually represents time for a continuous system and the variable n, which represents an integer value for a discrete system as shown.

Continuous-time and Discrete-time System

Interconnection of Systems

One of the practical aspects of electronic systems and block-diagram representation is that they can be combined together in either a series or parallel combinations to form much bigger systems. Many larger real systems are built using the interconnection of several sub-systems and by using block diagrams to represent each subsystem, we can build a graphical representation of the whole system being analysed.

When subsystems are combined to form a series circuit, the overall output at y(t) will be equivalent to the multiplication of the input signal x(t) as shown as the subsystems are

cascaded together.

Series Connected System

For a series connected continuous-time system, the output signal y(t) of the first subsystem, “A” becomes the input signal of the second subsystem, “B” whose output becomes the input of the third subsystem, “C” and so on through the series chain giving A x B x C, etc.

Then the original input signal is cascaded through a series connected system, so for two series connected subsystems, the equivalent single output will be equal to the multiplication of the systems, ie, y(t) = G1(s) x G2(s). Where G represents the transfer function of the subsystem.

Note that the term “Transfer Function” of a system refers to and is defined as being the mathematical relationship between the systems input and its output, or output/input and hence describes the behaviour of the system.

Also, for a series connected system, the order in which a series operation is performed does not matter with regards to the input and output signals as: G1(s) x G2(s) is the same as G2(s) x G1(s). An example of a simple series connected circuit could be a single microphone feeding an amplifier followed by a speaker.

Parallel Connected Electronic System

For a parallel connected continuous-time system, each subsystem receives the same input signal, and their individual outputs are summed together to produce an overall output, y(t). Then for two parallel connected subsystems, the equivalent single output will be the sum of the two individual inputs, ie, y(t) = G1(s) + G2(s).

An example of a simple parallel connected circuit could be several microphones feeding into a mixing desk which in turn feeds an amplifier and speaker system.

Electronic Feedback Systems

Another important interconnection of systems which is used extensively in control systems, is the “feedback configuration”. In feedback systems, a fraction of the output signal is “fed back” and either added to or subtracted from the original input signal. The result is that the output of the system is continually altering or updating its input with the purpose of modifying the response of a system to improve stability. A feedback system is also commonly referred to as a “Closed-loop System” as shown.

Closed-Loop Feedback System

Feedback systems are used a lot in most practical electronic system designs to help stabilise the system and to increase its control. If the feedback loop reduces the value of the original signal, the feedback loop is known as “negative feedback”. If the feedback loop adds to the value of the original signal, the feedback loop is known as “positive feedback”.

An example of a simple feedback system could be a thermostatically controlled heating system in the home. If the home is too hot, the feedback loop will switch “OFF” the heating system to make it cooler. If the home is too cold, the feedback loop will switch “ON” the heating system to make it warmer. In this instance, the system comprises of the heating system, the air temperature and the thermostatically controlled feedback loop.

Transfer Function of Systems

Any subsystem can be represented as a simple block with an input and output as shown. Generally, the input is designated as: θi and the output as: θo. The ratio of output over input represents the gain, ( G ) of the subsystem and is therefore defined as: G = θo/θi

In this case, G represents the Transfer Function of the system or subsystem. When discussing electronic systems in terms of their transfer function, the complex operator, s is used, then the equation for the gain is rewritten as: G(s) = θo(s)/θi(s)

Electronic System Summary

We have seen that a simple Electronic System consists of an input, a process, an output and possibly feedback. Electronic systems can be represented using interconnected block diagrams where the lines between each block or subsystem represents both the flow and direction of a signal through the system.

Block diagrams need not represent a simple single system but can represent very complex systems made from many interconnected subsystems. These subsystems can be connected together in series, parallel or combinations of both depending upon the flow of the signals.

We have also seen that electronic signals and systems can be of continuous-time or discrete-time in nature and may be analogue, digital or both. Feedback loops can be used be used to increase or reduce the performance of a particular system by providing better stability and control. Control is the process of making a system variable adhere to a particular value, called the reference value.

In the next tutorial about Electronic Systems, we will look at a types of electronic control system called an Open-loop System which generates an output signal, y(t) based on its present input values and as such does not monitor its output or make adjustments based on the condition of its output.

Electronics support system

Types of Electronic Performance Support Systems:

Their Characteristics and Range of Designs

An Electronic Performance Support System is, according to Barry Raybould, "a computer-based system that improves worker productivity by providing on-the-job access to integrated information, advice, and learning experiences" (Raybould, 1991). Gloria Gery defines it as "an integrated electronic environment that is available to and easily accessible by each employee and is structured to provide immediate, individualized on-line access to the full range of information, software, guidance, advice and assistance, data, images, tools, and assessment and monitoring systems to permit job performance with minimal support and intervention by others." (Gery, 1989).

Electronic performance support systems are used for:

task structuring support: help with how to do a task (procedures and processes),

access to knowledge bases (help user find information needed)

alternate forms of knowledge representation (multiple representations of knowledge, e.g., video, audio, text, image, data)

CHARACTERISTICS OF EPSS:

An electronic performance support system (EPSS) displays some or all of the following characteristics.

Computer-based: EPSSs are computer-based, which is what the &quotelectronic" in their name indicates. There have been older attempts at performance support systems, such as a series of manuals, job aids, and other paper material. But it wasn't until the advent of powerful multimedia computers that optimal performance support could be made possible. Optimal support includes quick and easy access to the information needed at the time the task is being performed.

Access during task: EPSSs provide access to the discrete, specific information needed to perform a task at the time the task is to be performed. This is a two-part characteristic: 1) access to the specific information needed to perform a task, and 2) access to the information at the time the task is to be performed. If one part of this characteristic does not exist, then the characteristic changes and is no longer a performance support characteristic. The discrete, specific information provided may be:

data: the type of data may be textual or numeric, such as prices, locations, and names. Or they may be visual, such as photographs and motion video footage. Or they may be audio, such as conversations, speeches, and music.

instruction: the instruction may be a list of steps to take, a motion video showing a procedure, or a simulation of a task that allows the user to practice.

advice: the advice may be an expert system that asks the user questions, then suggests the most appropriate procedure or step to do next.

tools: the software tools may be a spreadsheet, a statistical analysis package, and a program that controls industrial robots.

This availability of information, instruction, advice and tools makes much prior training unnecessary.

Used on the job: An EPSS provides information to people at their workstation on the job, or in simulations or other practice of the job. The information is provided at the worker's workstation as the worker sees a need for it. The EPSS can be used in simulations or other practice of the job, so that the worker learns both the information he or she will probably need when doing the job, and how to use the EPSS itself.

Controlled by the worker: The worker decides when and what information is needed. There is no need for a teacher, as the worker is guided by the needs of the task. The motivation is provided by the worker's desire to accomplish the task.

Reduce the need for prior training: The easy availability of the information needed to perform a task reduces the need for much (but probably not all) prior training in order to accomplish the task.

Easily updated: The very nature of an EPSS, that it provides the information needed to perform a task, requires that it be easily updatable, in order to keep the information that it provides current. The computerized nature of an EPSS makes updating faster and easier in some ways than in other media, such as print, video, or audio.

Fast access to information: The user must be able to access the needed information quickly when it is needed on the job. Otherwise the EPSS is no better than a set of manuals, which probably contain the information, but the information is difficult to find when needed.

Irrelevant information not included: The user is able to access only the specific, discrete information needed at that instant, instead of having to wade through loads of irrelevant information to find the few details needed. This is one of the problems with instruction that is not specific to a task; it forces the user to sift through it looking for the details needed. This sifting not only slows the user down, but can result in confusion.

Allow for different levels of knowledge in users: In order to speed up information access and understanding, an EPSS can provide minimal information for those who do not want details, yet, through the hypertext links in the databases and through optional tutorials, provide detail for those who do want more.

Allow for different learning styles: Through multimedia, an EPSS can accommodate users with varied learning styles, thus providing more optimal learning. The same information can be presented in visual, textual, and audio formats, with the user selecting the format.

Integrate information, advice, and learning experiences: An EPSS can integrate information, advice, and learning experiences for the user. For example, a database entry might describe a procedure. The user may not know if the procedure is the proper one to use, so he or she might turn to the advisor to find out. The advisor would ask the user some questions about what he or she needs to accomplish, then would suggest which procedure to use. The user might then access a tutorial on using the procedure, and practice it through a simulation, before actually performing the procedure.

Artificial intelligence: Artificial intelligence is an essential characteristic of EPSSs, according to Carr (Carr, 1992), but not according to Gery. I think that at this early stage of performance support system design and use, AI is not essential, but that eventually it will be one of the defining characteristics of EPSS. This will happen when research on EPSS and on AI has progressed further.

An EPSS is not an absolute system that contains all these characteristics. Rather, different systems will fall on a continuum of these characteristics. An EPSS displaying all these characteristics would be the ideal. Since performance support systems are still young, it is more likely that many will display only the key characteristics.

KEY CHARACTERISTICS

The key characteristics of EPSS which make them different from other computerized instructions or tools are the first five that were described above:

computer-based

provide access to the discrete, specific information needed to perform a task at the time the task is to be performed

used on the job, or in simulations or other practice of the job

controlled by the user

reduce the need for prior training in order to accomplish the task.

It is my opinion that these key characteristics are the minimum a program must have in order to called an EPSS. It must be computerized, by definition ("electronic"). It must provide the specific information needed to perform a task, otherwise it would be no different from traditional training, which provides the information needed, but includes irrelevant data as well. It must provide the specific information when it is needed, otherwise there is no difference between it and traditional training, which provides the information, but not when it is needed. It must allow the learner to decide when information is needed, and to access it, otherwise it is no different from teacher-controlled traditional training. And finally, the program must reduce the need for prior training in order to accomplish the task, otherwise why have a performance support system at all?

CLASSIFYING THE RANGE OF EPSS DESIGNS

Defining a range of technologies that could be classified as electronic performance support systems (EPSS) involves defining which and how many EPSS characteristics are necessary and are displayed, and how much of the design is new and how much is based on existing systems.

Perhaps the most important characteristics of an EPSS would be provided by the worker's environment. The work environment would have to allow the worker to decide when information and training is needed, and would have to provide the capability of the worker obtaining that information and training without outside intervention by supervisor or other staff. Management would have to expect the EPSS to provide the worker with certain training specific to job tasks, and thus would not provide that training elsewhere, nor expect the worker to obtain that training anywhere but from the EPSS.

EPSS characteristics have been described above. Let us now turn to an examination of the design of EPSSs.

EXTENT OF NEW EPSS DESIGN

The extent of the new design refers to how much of the design of the EPSS is new and how much is based on existing systems. According to Gery (Gery, 1993), the extent of the new design can be divided into four categories, listed here from least to most new design:

1) front end to existing system,

2) supplement to existing system,

3) stand-alone tool for specific tasks, and

4) new systems with integrated performance support.

Gery does not define these levels, since they were only mentioned in a brochure for a seminar, so I have added my own definitions to them.

Front end to existing system: Existing systems have usually not been designed for performance support. They may not allow non-linear hypertext links that improve ease of access to information, or may not allow easy updating of information. For this reason, designs that use existing systems are placed lower in the ranking than those that are designed specifically for electronic performance support.

A front end is an interface between a person and a software system. It helps the person to use the system, but it does not change the system itself, nor can it be used apart from the system. Microsoft Windows is a front end to the DOS operating system. It obviates the need for the user to remember DOS commands and syntax. A front end adds functionality to an existing system, but no additional information. It may act as a patch on a system that was not optimally designed for performance support.

Supplement to an existing system: A supplement to an existing system changes the existing system in some way. Hypertext links to a traditional database would be an example of a supplement to an existing system. Hypertext links allow a person to make non-linear connections between pieces of related information. It is like an electronic cross-referenced index, where the user decides what related information to look at next. Hypertext links in a database would permit the user to follow his or her interests in finding information in the database. A supplement may also act as a patch on a system not designed for performance support, although it does make changes within the existing system itself.

Stand-alone tools for specific tasks: Stand-alone tools for specific tasks are small EPSSs that are not built on existing systems, but are designed for narrow, specific tasks. A tutorial on how to use a computer program is an example of a stand-alone tool, since it can be used apart from the program itself, and supports only the use of that particular program.

New systems with integrated performance support: New systems with integrated performance support are designed with no reference to an existing system, and with performance support built in. They support a wide variety of job tasks, instead of narrow ones, as do the stand-alone tools described above. A new EPSS might provide the information, training and advice for all the tasks that a customer support representative would need in order to do his or her job.

RANGES OF TECHNOLOGIES CLASSIFIED AS EPSS

In order to describe the range of technologies that could be classified as electronic performance support, both the EPSS characteristics and the extent of the design must be taken into account. This relationship is illustrated in the graph below.

A minimal EPSS would have the lowest extent of design, and would exhibit only the key EPSS characteristics, no matter if a higher extent or more additional characteristics were needed to support the task or tasks.

A mid-level EPSS would have a higher extent of design, and additional EPSS characteristics beyond the key characteristics, but would not have all the necessary characteristics needed to support the task or tasks.

An optimal EPSS would have the highest extent of design and all the EPSS characteristics needed to support the task or tasks. All the characteristics may not be necessary for optimum support. An optimal EPSS would have the all the characteristics needed, and no unneeded ones.

MINIMAL EPSS

A minimal EPS system would be a front end that contains only the key EPSS characteristics, is built onto an existing system, does not change the existing system, and cannot stand alone.

Minimal Database EPSS: A database example of a minimal EPSS would be a computerized front end to a computerized database that would help the user find the needed information more easily and quickly. The training that had been needed previously to train the worker in how to find the information would no longer be necessary. This EPSS would be available to the worker at his or her worksite. The decision about when and what information to find would be up to the worker. (Part of the definition of this EPSS characteristic would have to include a work environment that allows the worker to decide when information is needed, and the capability of obtaining that information and training without outside intervention of supervisor or other staff.)

Minimal Help System EPSS: A Help system example of a minimal EPSS would be a computer interface to a Help system that makes it easier to use the Help system. It would be available at the worker's worksite, and would reduce the need for prior training on how to use the Help system. The worker would decide when he or she needed to use the Help system, and for what topic Help was needed.

MID-LEVEL EPSS

A mid-level EPSS would be a supplement to an existing system, and would contain not only the key EPSS characteristics, but additional ones as well. However, it would not contain all the EPSS characteristics needed to provide optimum support for the task or tasks.

Mid-Level Database EPSS: A mid-level version of the database model described earlier would change the extent of design to that of a supplement to the database itself. For example, adding non-linear hypertext links to the information in the database would allow the worker to more easily look at related information. This supplemental EPSS would contain the key characteristics: it would be computerized, would allow easy access to information when it is needed, would be available at the worker's worksite, would be controlled by the worker, and would reduce the need for prior training. It would contain additional EPSS characteristics, but not all the ones necessary to make an optimal system. The hypertext links would make allowances for different levels of knowledge in users. Users who needed more detail could use the hypertext links to find that detail. Those users who had more knowledge and didn't need to see detailed explanations would not have to see it. While it would be useful to be able to easily update the database, and to allow for different learning styles of the workers, trade-offs mean that the best EPSS for the time and money available was built.

Mid-Level Help System EPSS: A mid-level Help system might be tied into an existing program, thus making it context-sensitive. It would have the five key EPSS characteristics (be computerized, provide easy access to information when it is needed, be available at the worker's worksite, be controlled by the worker, and reduce the need for prior training), plus additional characteristics, although not all the ones needed to make it an optimal EPSS. This mid-level Help system might integrate information, advice, and learning experiences, but not allow for different levels of knowledge or different learning styles.

HIGH LEVEL EPS SYSTEMS

An optimal EPSS would not be based on an existing system, but would be designed specifically to contain all the EPSS characteristics necessary to optimally support a task or tasks.

Optimal Database EPSS: An optimal database EPSS would be computerized, and would allow easy access to the information the worker needs at the time it is needed. The database EPSS would be available at the worker's worksite. The worker would be the one to decide what information is needed and when, and would then use the EPSS to find the information. The need for prior training to use the database would be reduced.

In addition, the database could provide access to other software to help the worker do his or her job, such as spreadsheet and word processing software. The EPSS would integrate tutorials and expert systems into the database, both in order to make them context-sensitive, and to allow them to share data. The information in the database would be presented in visual, aural and textual formats in order to accommodate the different learning styles of the workers. The information would be linked with related information via non-linear hypertext links, providing fast access to information, and allowing for different levels of knowledge in users. And finally, the database would be designed for easy updating. This database was designed and built for Prime Computer, Inc., by Ariel Performance Support Systems.

Optimal Help System EPSS: An optimal Help system would display the five key EPSS characteristics, and any additional ones needed to optimally support the task or tasks. It would be context-sensitive to the part of the program with which the worker needed help. The Help system would use its intelligence to notice if a worker made two or more related mistakes when using the program. It would then offer advice, information, or the opportunity for the worker to take a tutorial on the topic. The Help system would offer its information in different modes (aural, visual, or textual) to the worker, who would select the mode desired depending on the learning style of the worker. The Help system would be designed for easy updating, and could allow the worker to annotate the Help screens with his or her own notes. This Help system was designed and built by Ziff Technologies and Comware, Inc., for Microsoft's Word for Windows program.

There are many configurations of computer support that can be classified as electronic performance support systems, but they range from low level to optimal support. This description is a brief overview of the current state of the design of such systems.

Textron System

Electronic Systems

When lives are at stake, it’s imperative that critical mission systems perform precisely and reliably every time. Electronic Systems provides advanced training aids, confidence testers and support to those who imagine, manipulate and exploit the electromagnetic spectrum. So you can dominate modern warfare with confidence.

1.Products

Universal Test Set (UTS™)

The AN/GLM -11 V(1) UTS (NSN 5865-01-580-1528) and AN/GLM-11 V(2) are end-to-end confidence testers for communications equipment, as well as the primary tester for Counter Remote Control Improvised Explosive Device (RCIED) Electronic Warfare, or CREW, systems.

These systems are capable of stimulating electronic support measures and measurement of electronic countermeasure radio frequency jamming codes. It is also used for systems integration laboratory, depot and flight line confidence testing.

Reconfigurable Trainer

Our customizable Reconfigurable Trainer architecture is a versatile and highly effective foundation for electronic warfare simulators, virtual maintenance trainers, communications equipment trainers, crew simulators, mission rehearsal trainers, manned-unmanned teaming trainers, space command and control trainers, and other complex military applications.

Hosted on commercial, off-the-shelf PCs, the Reconfigurable Trainer has been used as the basis for both the T25 Simulator for Electronic Combat Training, as well as the F-35 Lightning II Aircraft Systems Maintenance Trainer.

Our equipment model library contains more than a hundred installed systems across radar, electronic warfare, communications, navigation, signals intelligent and other user-defined systems.

Range Simulation Equipment

Success on the training range sows mission success. Skilled students with optimal training outcomes not only understand the equipment on which they’ve received training, but can perform to expectations in the field with that equipment and in accordance with doctrine.

Textron Systems’ training range simulation equipment delivers the same rich, high-fidelity environment enjoyed in systems integration laboratories and flight line applications – for seamless interoperability and maximized training outcomes.

Learn more about our range simulation systems:

• Our new Phantom™ Dual Threat Emitter is a handheld device designed to stimulate both laser warning receivers and missile warning sensors. Threat scenarios can be a combined laser and ultraviolet (UV) stimulation, or separate.
• The Man-Portable Aircraft Survivability Trainer, or MAST™, accurately replicates the visual effects of an infrared (IR) threat-based weapon to stimulate UV-based aircraft survivability equipment systems for more realistic aircrew training events.
• Our Portable Range Threat Simulator, or PRTS™, uses the sophisticated radio frequency capability of our Model 527™ to generate complex, multispectral signals for search, launch, track and other scenarios.
• The Griffen™ -25 and -50 are medium-range electro-optic test sets designed to stimulate UV missile warning systems at range, enabling opposing forces training. It also can be utilized for flight line testing.
• The Mallina™ product family, including the UV LED Mallina and the NemesisTM IR Beacon Mallina, are designed to stimulate missile warning systems at varied standoff ranges. Ideally suited for aircraft survivability equipment aircrew training and survivability equipment test and evaluation, the system can be remotely operated.
• The Phoenix Lite™ is a medium-range, electro-optic system designed to stimulate one- and two-color IR missile warning systems, as well as directed IR countermeasure, or DIRCM, fine-track sensors. 

Radio Frequency (RF) Synthesizers

Textron Systems’ trusted RF product suite leads the industry with interoperable, customizable and powerful test and simulation support from the lab to the flight line. Keep your systems operating at peak performance and equip them for greater application flexibility with our RF synthesizers.

Our VXI and LAN Controlled RF Source in-work minimize signal loss and noise for maximum signal density and simulation power. They are utilized in many RF Automated Test Equipment applications, including aviation, surface vessels and space.

Our state-of-the-art electronic warfare simulator uses identical phase coherent, VME direct digital Synthetic Stimulus Instruments (SSIs) as the RF signal source.. Our Advanced Architecture Phase Amplitude and Time Simulator (A2PATS™) system, which uses the VME SSI, can be tailored upward with varying numbers of SSIs per port to support even the most stringent and demanding test scenarios.

We also offer RF synthesizers for our JSECST™ (Joint Service Electronic Combat Systems Tester) flight line test set, the Lab JSECST™, the Model 527™ Radar Signal Simulator andLab Model 527™ and other customer-defined uses.

Preflight Testers

Thousands of Textron Systems’ preflight testers are in use around the world, across the U.S. Department of Defense and allied nations. These are the systems of choice for some of the world’s most sophisticated aircraft platforms. Our precise and user-friendly systems keep personnel and equipment safe with reliable assessment of mission-readiness – covering electronic warfare, communications, navigation and other subsystems.

Our systems are ruggedized, portable and easy to use. We offer a comprehensive range of preflight testers to address your most complex requirements:

• Our Baringa™ products are missile warning system test sets, with the basic Baringa 5.5 for all UV missile warning systems including the AN/AAR-47, -54, -57 and -60. The Infrared (IR) Baringa can be used to stimulate one- or two-color IR missile warning systems.
• The Solent™ IR Jammer Test Set is used to verify IR countermeasure systems in a completely unclassified manner. It measures both the modulation characteristics of the IR countermeasure systems, as well as the radiant intensity of their jamming signals.
• The Hydra™ test set is used to stimulate laser warning receiver systems by simulating a number of laser threats, including beam riders, target designators and range finders. A laboratory variant, the Hydra SIL™ also is available to better accommodate the needs of systems integration laboratories.
• Our Model 527™ validates electronic warfare radar warning receiver systems on operational aircraft through free-space radiation functional testing.
• The Multi-Spectral Test System (MSTS™) verifies radars, radar warning receivers, missile warning systems, laser warning systems and other radio frequency systems onboard aircraft. It builds on the success of our MEON™, an end-to-end flight line confidence test set for directional infrared countermeasure, or DIRCM, and ultraviolet missile systems.

Multi-Spectral Test System (MSTS) and MEON™

Our handheld MSTS verifies radars, radar warning receivers, missile warning systems, laser warning systems and other survivability equipment onboard aircraft, providing operators the tools they need to confidently validate the operational status of installed electronic combat systems. And with setup times of five minutes or less, preflight checks are as efficient as they are effective.

The MSTS builds on the proven success of the MEON, our end-to-end flight line confidence test set for directional infrared countermeasure, or DIRCM, and ultraviolet missile systems. The MEON is ruggedized, battery-operated, and can be handheld or mounted on a tripod.

Model 527™

Textron Systems’ Model 527 Radar Signal Simulator (NSN 6949-01-563-1116 and P/N 39300-40002-10; NSN 6940-01-524-5640 and P/N 40291-40002-10) validates electronic warfare radar warning receiver systems – including antennas, transmission lines, radomes, cockpit displays and controls – on operational aircraft through free-space radiation functional testing. It also can be used for preflight verification of avionics systems (B-kit) and transmission paths (A-kit). The lightweight, battery-powered system also is fully compatible with the company’s electro-optic/infrared/laser simulators, allowing a true, multispectral test package.

The Lab Model 527 takes this same functionality from the flight line to research facilities, offering many threat simulation options, from simple continuous wave or pulsed single emitters to complex, multiplexed radio frequency emitters modeling several threats at once. This capability allows sophisticated, high-fidelity simulated environments to be developed for verification of radar warning receiver capabilities.

The Model 527 also serves as the radio frequency signal generator for our Portable Range Threat Simulator (PRTSTM), adding even greater functionality and value.

Advanced Boresight Equipment (ABE®)

Textron Systems’ ABE (NSN 4920-01-575-4554 for the Model 310A Green; NSN 4920-01-540-4173 for the AN/UVM-34 Model 310A White) is a state-of-the-art, gyro-stabilized, electro-optical angular measurement system designed to align mission systems on any land, sea or air vehicle.

With measurement accuracy of up to 0.1 milliradian and a full, 360-degree measurement range, our ABE system is a trusted flight line tester for precise, repeatable measurements, as well as minimized boresight time, training and manpower requirements.

Our ABE system is comprised of our common core test set (Models 300, 310, 310A and 410A), plus a platform-specific personality module to tailor the operating characteristics of the tester to the aircraft, vehicle or vessel under test. Adapter sets are available for dozens of platforms, including F-35 variants, the AH-64D, AH-1 variants, C-130 variants, C-17, H-60 variants, Eurofighter and Nimrod. A full list of currently supported platforms is available here.

ABE has been used across the U.S. Department of Defense, and by numerous international allies, for years – the trusted system for fast, accurate results every time. 

Joint Service Electronic Combat Systems Tester

The AN/USM-670A JSECST™ (NSN 4920-01-618-5101) is a flight line test set for critical aircraft electronic warfare, communications and navigation systems. Trusted across the U.S. Department of Defense and numerous allied nations, the JSECST can be utilized for dozens of platforms.

Comprised of a common Core Test Set and a tailored Test Program Set with antenna couplers or interface adaptors to customize performance characteristics to the platform under test. The most recent JSECST upgrade adds decades of system life. It also delivers the capability to test a range of new mission-critical aircraft systems including electronic warfare, communications and navigation. A full list of currently supported aircraft platforms is availablehere.

In addition, we have translated all of the same capability and functionality from the flight line to our Laboratory JSECST (NSN 6940-01-619-8416), designed for the rigors of the systems integration laboratory.

Hundreds of JSECST systems are fielded around the world, testing dozens of fixed-wing aircraft and rotorcraft. Trust Textron Systems for reliable and precise flight line testing.

Advanced Architecture Phase Amplitude and Time Simulator (A2PATS™)

There is only one A2PATS – our advanced electromagnetic environment electronic warfare (EW), communications and electronic intelligence simulator provides unmatched performance and flexibility, verifying that U.S. and allied aircraft EW systems can precisely locate, identify and defend against virtually all ground-based and surface-to-air missile threats. Systems use threat translation technology to incorporate legacy threat libraries for backward compatibility.

Electronic Systems' plug-and-play, continuously aligned system uses identical phase coherent, direct digital Synthetic Stimulus Instruments (SSIs) as the radio frequency source for all signals. Customers can build their A2PATS capability as time, budget and requirements allow. With the addition of cabinets and SSIs, we can create signal density for an even richer, more high-fidelity simulated environment.

Let us help you build your ideal A2PATS system:

• Single or multiple cabinets
• Single or multiple radio frequency (SSI)
• Number of SSIs per output port