Report No.

Defect investigation Closure report for EP Console

A/TS/RGCS/DI- (4769 196 201 55)
Closure/EP/001
Dated: 28/08/2017

Unit Sl. No. 05, 07, 06, 03, 08, 02

DI References DI Meetings were conducted regarding EP Console failures and certain
recommendations were suggested as a outcome of DI meetings. All references are as
per ‘List of Enclosures’ which is brought out in next section and attached for easy
reference.
Summary of Summary of recommendations and status is as follows:
recommendations
& status  Technical Memo to be generated for the Life Cycle Profile of integrated Joystick
assembly - Completed
 Data for mechanical life of integrated joystick assembly used in EP Consoles
developed for MK-II & MK-III GCS to be generated for 50000 actuation cycles
- Completed
 Identification of any wiring related workmanship issues in EP Boxes offered for
DI to be carried out. – Completed as per requirement
 Strengthening of the joystick lever attached to spring, through suitable industrial
grade adhesive material to be carried out. - Implemented
 Screening of integrated joystick assembly used in EP consoles supplied under
GCS MK-III, for 1000 actuation cycles. Data to be observed and recorded.
- Implemented
 Trim Tab of Throttle Joystick was not locked to centre position with Joystick
body - Implemented

Summary of • SOP is prepared for rewiring of EP Console approved by ADE and CEMILAC.
activities • Activities as per approved SOP document are carried out on both units.
• Loctite 406 is applied on Trim tab of Throttle Joystick.
• Araldite is applied on Spring lever of Joysticks.
• Initial functional checks, Delta ESS and Final functional checks are carried out on
both units. Functionality found satisfactory.
• Slight crack is observed on bottom of Joystick shaft in both units 05 and 07
during physical inspection. Based on physical observation found in Joysticks of
both units, DI meetings were conducted on 10/08/17 and 21/08/17. With reference
to DI Committee meeting held on 21/08/2017 at CEMILAC, it was decided that
for R2 - EP Consoles – MK-II subject to rework following activities were
mandated:
i. Physical inspection to be carried out at 20x magnification for identification of
hairline cracks.
ii. Enhanced arresting mechanism for joystick shaft to be used during vibration
tests.
iii. Carry out vibration on one unit. Perform mechanical and functional clearance
checks post the vibration.
iv. On successful clearance, carry out Delta ESS tests on the remaining units.
  On 26/8/2017, in presence of BEL, CARAVEL, ADE, ORDAQA and CEMILAC
reps, EP Console Sl. No. 3 was subject to examination for hairline cracks and
joystick shaft arrested by enhanced arresting mechanism. No cracks were found
before vibration. The unit was mounted on jig and pre-vibration functional checks
performed. Unit was subject to vibration. Post vibration, functional check failure
observed. Post vibration, it was found that the Rudder / Throttle joystick assembly
had sustained a failure on the Throttle axis. A part had broken where the joystick
holds the shaft of potentiometer. For more details, refer vibration report of 003
attached in Annexure – M.

 As the unit had not cleared vibration tests, it was discussed between ADE and
CEMILAC, in accordance with mail reference from ADE dt 28/8/17, not to carry
out vibration tests on the remaining units.

 Summary of activities carried out on EP Consoles 05, 07, 06, 03, 02, 08 is brought
out in annexure – L for reference.

DI Conclusion  Design needs to be improved to meet full ESS requirement for subsequent lot
(MK III units)
 MK II Units will be cleared based on thermal cycle performance only.
 Above MK II units will be inspected for any abnormality after each flight as per
mandate of DI committee.
 LIST OF ENCLOSURES
ANNEXURE – A: DI report for EPC #5 for DI meeting on 28/11/2016

ANNEXURE – B: DI report for EPC #8 for DI meeting on 13/12/2016

ANNEXURE – C: MoM on 03/01/2017 for R-2 EP Console Checkpoints

ANNEXURE – D: MoM of DI Meeting for EPC #5 & #7 - 23/06/2017
ANNEXURE – E: TM Joystick Operational Cycle Estimation 30/6/2017

ANNEXURE – F: Proposal for EPC Mk-II rewiring - 05/07/2017

ANNEXURE – G: RoD on Validation of Improvements –EPC Mk-II&III-

on 11/07/2017

ANNEXURE – H: Call for DI meeting for EPC #5, #7,#8 on 08/8/2017

ANNEXURE – I: MoM of DI Meeting for EPC #5, #7,#8 on 10/8/2017

ANNEXURE – J: BEL Work Done Report on EPC #5,7,2,6 – 14/8/17

ANNEXURE – K: CEMILAC Letter- QRM on EP Console – 16/8/17

ANNEXURE – L: WORK DONE REPORT

ANNEXURE – M: VIBRATION REPORT OF MKII EP CONSOLE (S/N: 003)

ANNEXURE –N: ADE Mail for vibration waiveoff

ANNEXURE - A
ANNEXURE – B
 ANNEXURE – C
MoM on 03-01-2017 between ADE, BEL & M/s Caravel Infosystems - R-2 EP Console @ADE

Participants:
1. Shri S.K.Singh, Sc.’F’ (R2-PD(PGDT)) & Team – ADE
2. Ms. Gayatri Sivakumar, Manager, Avionics & Testing and Team – BEL
3. Mr. Imran, Manager, & Team – M/s Caravel Infosystems
Following points were the outcome of discussions :
It was agreed upon that a screening mechanism has to be put in place for the standalone
Joystick (without potentiometer) configuration, standalone potentiometer configuration, Assembled
configuration of Joystick with potentiometer and Integrated Joystick assembly wired to EP Console.
Following points were the recommendations agreed upon after discussions:
1. Standalone Joystick part :
a) X-Y Connecting rod hinge pull test to be done where metal rods are embedded in plastic
b) Joystick top lever fitment to be firm and verified (should not give way for rotation)
c) None of the assembled plastic parts of the joystick to be at marginal level of fitment and
functionality. Fitment to be verified
d) Spring stiffness to be checked and adjusted against specs for
i. Force required for deflection of one step
ii. Force required for full deflection
e) Joystick lever mechanical travel from centre to extremes on both sides must be same
f) Trim tab centre blind locking to be ensured
g) Trim tab mechanical travel from centre to be equidistant on both sides
h) Each trim notch to be clearly identifiable during trim tab movement
2. Standalone Potentiometer part :
a) Potentiometer repeatability test to be conducted for 10000 cycles for all potentiometers of
every console.
b) Inspection for smooth rotational movement of shaft with no horizontal or lateral play and
visual observation to ensure no physical damage to the component
3. Joystick assembled with Potentiometer:
a) No play of the potentiometer body to be observed after fitment to the joystick. Fitment to
be firm and verified
b) Joystick travel to be smooth. No rubbing / undue friction between joystick frame and the
moving parts to be ensured. Any unsymmetrical displacement post assembly to be verified.
c) Resistance variation for Joystick variations from centre to extremes must be same in both
directions for return to centre joysticks. Same applies to displacement of trim tabs from
centre to extremes
4. Integrated joystick in wired configuration in EP Console :
a) Heat – shrink sleeves to be provided of sufficient length at wire- terminal solder junctions to
ensure adequate strain relief
b) Soldering temperature not to exceed potentiometer manufacturer recommendations
c) No burn marks to be observed on potentiometer body due to soldering. Wiring assembly with
 sufficient slack to be provided to avoid any pullback during joystick operation
d) Branch wiring scheme to be followed when shorting contacts
e) Equidistant mechanical & electrical travel of Main joystick lever and trim tabs to be re-verified

 Vendor and BEL to generate a Quality Plan Document for the screening process
 Wiring template to be made on which switches would be assembled and wired and then
transferred to the EP Console
 Potting on switch terminals to be carried out.
ANNEXURE – D
ANNEXURE – E
ANNEXURE – F
ANNEXURE – G
ANNEXURE – H
ANNEXURE – I
ANNEXURE – J
ANNEXURE – K
 ANNEXURE – L

Work done Report- R2 - EP Console Mk-II

Sl. Unit Fault Details Date Corrective Action

No. No.
1 5 Throttle Potentiometer Pin 22/11/2016 Potentiometer Replaced.
found broken Delta ESS Carried out. Unit
functional as per specs
2 Wire desoldering at 23/06/2017 Rework done. Delta ESS Carried
‘Decrement’ Intensity Push out.
Button Switch
3 During delta ESS tests, crack on ---- Joystick Base replaced and
Joystick Base observed functional test performed.
4 8 Joystick not moving beyond 13/12/2016 Joystick Assembly Replaced.
middle position. Shaft pin Delta ESS Carried out. Unit
potruding outwards functional as per specs
5 Pitch Pot terminal- wire 08/08/2017 Activities under progress
interface break
6 7 Failure of spring return to 23/06/2017 Spring lever part replaced after
centre mechanism. Mechanical strengthening. Delta ESS Carried
failure of spring lever out.
7 During delta ESS tests, crack on ---- Joystick Base replaced and
Joystick Base observed functional test performed.
8 6 Minor crack in Joystick Base --- Joystick Base replaced, Thermal
observed Cycling and functional test
performed
9 3 Received for rewiring SOP 26/08/2017 Rework done. Delta Carried out.
10 2 Received for rewiring SOP 28/08/2017 Activities under progress
In addition to above following tasks were performed :
1. Screening mechanism for Standalone Joystick part, Standalone Potentiometer part ,
Joystick assembled with Potentiometer, Integrated joystick in wired configuration in
EP Console and action plan arrived at a meeting between BEL, ADE and CRI Reps on
03/01/2017 for EPC MK-III.
2. Data for EPC MK-II & MK-III Joysticks generated by carrying out 50000 actuation
cycles
3. Technical Memo for EPC joystick operational cycle estimation issued.
4. Joystick spring lever strengthening through application of industrial grade adhesive
being carried out on all eight EPC-MK-II Consoles
5. Resoldering and potting of every wire is being made at switch and potentiometer
contacts as per BEL process standards by BEL operators for all eight EP MK-II
Consoles.
6. Delta ESS Tests are being carried out on the reworked boxes.
 ANNEXURE – M

VIBRATION REPORT OF MKII EP CONSOLE (S/N: 003)

Date:28-08-2017

1) As per the decision of Quality review meeting on MKII EP console units held at
CEMILAC on 21/08/2017, EPC 003 was identified for subjecting to Random vibration
(Z Axis for 5 minutes) in presence of ADE, CEMILAC, ORDAQA and BEL reps on
26-08-2017.
2) Pre vibration physical inspection and functionality tests were carried out in presence
of ADE rep and performance was found satisfactory
3) After concurrence from ADE &CEMILAC rep, a nylon strip (as shown in fig1) was
used along with the fixture to arrest the movement of joysticks during vibration.

Fig 1

4) EPC 003 was subjected to Random vibration (Z Axis for 5 minutes) in presence of
ADE, CEMILAC, ORDAQA and BEL reps
5) During vibration electrical parameters were monitored as per the approved ATP and
results were satisfactory.
6) However during post vibration functionality testing, it was observed that Throttle
joystick value update was not happening as per ATP in the Test software GUI
7) Hence, to check the cause of this failure, bottom cover of the EP console unit was
removed to access the joystick in presence of all reps.
8) During inspection, damage in the throttle joystick was observed (as shown in fig2). A
part had broken where the joystick holds the shaft of potentiometer. Because of this
the movement of potentiometer was not happening and hence, the value update was
not happening in the test software.

Fig 2
9) Owing to urgent requirement of EP Console in the field, it was decided by ADE, with
concurrence of CEMILAC, to replace the damaged joystick of EPC 003 with joystick
of EPC 008 and dispatch EPC 003 unit.
10) The joystick was replaced and post replacement electrical test & calibration tests
were performed. Results are found to be satisfactory. Unit is visually Inspected and
found to be satisfactory.
11) Further to that, ADE has discussed with CEMILAC for waive off of Vibration for the
present batch of Mk-II which have under gone DI committee recommendations SOP
changes.
12) With above CEMILAC clearance, unit sl.no:003 is dispatched to
ADE.
 ANNEXURE -N

From: "ram mahadev harish" <may2003ram@rediffmail.com>

Subject: Concurrence of CEMILAC FOR THERMAL CYCLING ON EP
CONSOLES
Date: Mon, August 28, 2017 4:48 pm
To: gayatria@bel.co.in,manjulajs@bel.co.in
Cc: sksingh@ade.drdo.in
Ma'am
Refer Telecon on 28/8/17. CEMILAC has given concurrence to performing only thermal
cycle on the reworked units. CE(CEMILAC) has been briefed by PGD -R2 regarding the
same.
Regards
Harish
ADE
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