IEEE TRANSACTIONS ON AEROSPACE-SUPPORT CONFERENCE PROCEDURES
DESIGN 4HIIOSOPHY OF AN AUTOlI'ATIC
ChECKOUT AND LALUNGH SYSTal FOR A DRONE
Harry Halton
Canadair Ltd.
SUSD'LRY
A system is described by means of which
a drone can be automaticallv checked out
and launched from a remote location over a
period of less than 12 minutes from "go-
ahead" by relatively low skilled personnel.
The features of the system are its
simplicity, the rapidity with which the
complete sequence is accomplished and the
ease of fault recognition.
One of the more interesting design
problems solved was the automatic control
and monitoring of turbojet engine operation.
INTRODUCTION
An Elementary Description of the Drone
The checkout and launch equipment, which
is the subject matter of this paper, was
designed by Canadair Limited for use with
a short range reconnaissance drone with a
camera for its payload.
The drone has a jet engine for its
sustaining power plant and is boosted into
flight from an elevated launcher by means
of a solid propellant rocket motor.
The drone flies a predetermined ground
track at a preset altitude by means of a
3-axis autopilot. It is guided to the
landing area by a localizer type homing
system in conjunction with the autopilot
and recovery is effected by means of a
parachute and air inflated landing bags.
All of these functions are commanded auto-
matically by programming equipment entirely
integral within the drone.
Basic Checkout and Launch Equipment
Philosophy
Ground support equipment has in many
programs been an item which, though recog-
nized as a necessity, received too little
attention too late to achieve anything
but a compromise between the optimur and
538
the calendar. Fortunately, on this
Canadair drone program the design of the
GSE has been closely integrated and suit-
ably timed with the design of the airborne
equipment since the very early definition
stages. Thus, operational requirements
have provided the primary design criteria
for both the airborne and ground equipment.
It has been clear from the very start
of the program that in order to meet the
tactical requirements and the associated
reaction times the operational checkout
and launch countdown must be automatically
sequenced. From a cost/reliability stand-
point, it was considered essential to keep
the electrical/electronics parts count to
an absolute minimum consistent with a high
confidence factor for the successful
accomplishment of a mission. These
considerations were also in unison with
the whole of the concept for a simple un-
sophisticated system.
Remote operation and readout capability
from initial "turn-on" through launch was
considered an essential capability.
GENERAL DESCRIPTION
The checkout and launch equipment under
discussion is required to provide com-
pletely automatic preflight checkout
functions as well as launch sequencing for
the drone. In doing so, the equipment
will be required to operate not only in
conjunction with the drone which it is
controlling, but other ancillary and
associated ground support equipment such
as an air supply unit, a fuel supply unit,
an electrical ground power supply unit and
finally the launcher itself. A simplified
schematic of such a system is shown in
Figure 1. Essentially in this paper only
the heavily outlined automatic checkout
and launch equipment will be discussed
though, where necessary, its integration
with the remainder of the ground support
equipment will be mentioned.
In order to achieve a simple mainte-
nance concept, it was decided to design
 IEEE TRANSACTIONS ON AEROSPACE - SUPPORT CONFERENCE PROCEDURES
the system in a modular plug-in construct-
ion as shown in Table I. The modules are
shown schematically in Figure 2.
In order that a conceptual design of
the systemts launch control functions
could be established, it was necessary to
enumerate all of the necessary launch
control functions. These are shown in
Table II.
Checkout Functions
Several basic philosophical principles
governed the conceptual design of the
checkout functions of the equipment.
A. The checkout equipment and the drone
must be designed as one system.
B. Prelaunch checkout is not the place to
confirm the design of the system, but
sirnply to confirm that the system is
operative.
C. A simple go-no/go answer is adequate to
make the most important maintenance
decisions.
D. Integrated checkout equipment is
essential. (The alternative to inte-
grated equipment, if this be an
alternative, would be separate checkout
equipment and launch control equipment,
separate means of checking the recovery
functions, homing functions, camera
functions, etc.. Such equipment would
most certainly be more expensive,
besides requiring higher operator
skills and being tactically useless).
E. A thorough analysis of the test equip-
ment mission and of the environment of
its use is absolutely essential.
F. Lowest possible operator skill levels
should be required.
G. The checkout equipment should not de-
clare a drone faulty when in fact no
fault exists.
Detailed examination of these princi-
ples then led, more or less automatically,
to the following considerations and
finally to the following decisions:
A. The checkout sequence would have to be
automatic. An automatic sequence would
have the following advantages:
(i) Speed
(ii) Reduction of "on" time of equipment
being tested resulting in longer
equipnent service life.
(iii) Mtinimization of training requirements
for user personnel.
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(iv) Reduction in a requirement for human
operator judgement.
(v) A high degree of unifornity of test.
B. There should be no "warm-up" time re-
quired for the checkout equipment.
C. The selection and number of functions
tested should be kept to a minimun con-
sistent with the philosophy that a go-
no/go check should establish a high
level of confidence for the successful
accomplishment of the drone's mission.
D. It appeared that open loop testing was
completely adequate and entirely com-
patible with the concept of simplicity.
(Admittedly, closed loop testing involv-
ing, as it does, the imparting of
dynamic motion to the system under test,
will yield the greatest confidence
factor. Closed loop testing, however,
requires very complex and expensive
checkout equipnent).
The functions selected for checkout are
tabulated in Table III.
It was also considered that to properly
carry out the objectives of an R & D pro-
gram the full tactical version of the
launch and checkout equipment should be
evaluated with the flying hardware, and
this is presently under way.
DETAIL EQUIPMENT DESIGN
The results of the design, as far as the
checkout and launch sequence are concerned,
are shown diagrammatically in Figure 3.
The principle of simplicity of the sys-
tem has been preserved, as evidenced by the
major parts count shown in Table IV.
The remotely operated control unit is
shown in Figure 4. From this figure it
will be seen that the launch functions are
essentially on the right hand third of the
panel whereas the checkout functions
occupy the left hand two thirds of the
panel.
Figure 5 shows a typical module. This
particular one happens to be the launch
unit.
This is now an appropriate point to
describe the details of the checkout and
launch sequence. (See also Figure 3).
The following, then, is the standard
checkout and launch sequence when no fault
occurs.
1. All umbilical connections are made to
the drone.
 IEEE TRANSACTIONS ON AEROSPACE-SUPPORT CONFERENCE PROCEDURES
2. The control unit (attached by a lengthy
cable to the remainder of the system)
is moved to a remote position.
3. The IRIMiARY Il't;ER switch is actuated
and the POWER ON light illuminates.
The EXTERNiiL IPOtWER OFF light
illuminates.
4. The DRONE SELECTOR switch is actuated
(by depressing the face of the light)
and the SELECTED DRONE light
illuminates.
5. During the next 8 minutes the di-
rectional gyro in the drone will be run
up to speed and will be erected and the
altitude control heater will stabilize
(no operator action will be required).
6. At the end of the eight minute period
the EXTERNAL POW!ER ON light will start
flashing and the DRONE READY light will
illuminate.
7. The DRONE READY light is depressed and
the EXTERNAL PO'.IER ON light is
depressed. The EXTERN4ATL POW.,1ER ON light
is illuminated continuously and the
EXTERNAL POWER OFF light is
extinguished.
8. After 1 second a warning light at the
launcher flashes and a horn howls in-
dicating that a launch is imminent.
9. During the next two minutes the di-
rectional irro will be automatically
nulled.
10. At the end of the two minutes the STEP
light will commence to flash indicating
that the system is ready for checkout.
11. The AUTO light is depressed and the
AUTO light becomes illuminated
continuously.
12. After 1 second the automatic checking
sequence commences and a satisfactory
checkout condition is indicated by the
GO light flashing on once every second,
together with the corresponding func-
tion light. No operator action is
required. (The circuitry used for this
checkout sequence is described later in
the paper).
13. Upon completion of the checkout
sequence (having sampled 25 separate
drone circuits - see Table III) the
START LAUNCH lighlt commences to flash.
14. The launch system is then armed by in-
serting and turning a specially pro-
vided arming key. The ARMI3 light
commences to flash.
15. The STAsT LAUNCH light is depressed and
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the START LAUNICH light will cease to
flash and will become illuminated. The
engine commences to ruri up.
16. After 1 second the EXTERNAL FUEL ON
light becomes illuminated.
17. After 5 seconds the COMBUSTION light
becomes illuminated and the engirne
accelerates to idling RPI.
18. Ihen engine reaches idling RPM the
ENiGIN'E IDLE light becomes illuminated.
The engine is allowed to stabilize at
this RPM for approximately 15 seconds,
at which time the fuel schedule is
changed to allow engine to accelerate
to full power. Simultaneously the
1\IGINE IDLE light will become
extinguiished.
19. As engine reaches rated RPMI and jet
pipe temnperature, the RpM. and
TPM'ERATURE lights will become
illuminated.
20. After 1 second the ETELRNAL FUEL ONl and
COMBUSTION lights will become ex-
tinguished and fuel and electrical
power supply is switched from external
to internal drone services. The
INTERNAL POWER ON light becomes
illwninated,
21. After 6 seconds the umbilical plugs
are released and after they have
cleared the drone booster ignition is
applied and the drone is launched.
22. After 100 milliseconds the UMBILICAL
CLEAR light will be illuminated.
It will be noted that the entire launch
sequence, i.e. from the point where the
START LAUNJCH light is depressed to the
point where drone becomes airborne (items
15 through 21 above), is entirely auto-
matic anrd no action by the ooerator is,
therefore, required. Similarly, the en-
tire checkout sequence (items 11 and 12
above) is entirely automatic and no action
by the operator is required if the check-
out proceeds without a fault. It may,
therefore, be interesting to examine the
types of faults which may be discovered by
the equipment and the operator action re-
quired to handle them:
1. During Automatic Checkout Sequence:
Should any one of the 25 automatically
scanned circuits be found out of toler-
ance, the checkout sequence will auto-
matically stop at this point, the NO-
GO light will be illuminated, and
simultaneously the light describing
the particular function will remain
illuminated. The operator may then
chose to troubleshoot the fault or he
 IEEE TRANSACTIONS ON AEROSPACE - SUPPORT CONFERENCE PROCEDURES
may decide to confirm the fault by
repeating the checkout by depressing
the HCME light, or finally he may de-
cide to continue the checkout by
depressing the STEP light.
2. During thelAutomatic Launch Sequence:
The launching sequence will be auto-
matically aborted in the event any one
of the followring faults are established
by the equipment:
(a) If the sustainer engine does not
light-up within 5 seconds after
launch sequence has been initiated.
(b) Engine does not idle satisfactorily.
(c) Engine does not reach rated RPM
within 60 seconds.
(d) Engine overspeeds.
(e) Engine does not reach rated JPT
within 60 seconds.
(f) Engine exceeds maximum JPT limit.
No action is required by the operator,
and the system automatically prevents a
relight attempt within 2 minutes of the
abort to ensure fuel drainage from the
engine. A typical abort sequence is shown
in Figure 7.
Typical Circuits
It is considered that the circuit
associated with one step in the automatic
checking sequence is perhaps typical of
the circuit design used in the equipnent.
During this phase of the checkout sequence
one wafer of the stepping switch (SS wafer
C in Figure 6) is used to energize relays
K2 and K3 alternately as stepping switch
is moving from contact to contact. Other
wafers of the stepping switch (not shown
in figure) are used to inject the neces-
sary stimuli into the tested circuit and
presenting the tested circuit parameters
as well as internally generated comparator
voltages to two voltage comparators (one
high and one low) which are so arranged
that the normally open contacts, HL-1 and
HL-2 close when the tested voltage is
below the high limit, and LL-1 and LL-2
close when the tested voltage is above the
low limit.
Thus, for a satisfactory test condition,
the following is the sequence of events:
1. Relay K2 or K3 will be energized -
assume K2 to be energized.
2. Contacts LL-1 and HL-l of comparators
close and relay K23 will be energized.
The one second time delay relay Kl will
541
be energized via contacts K2-2 and
K23-1 as well as K2-1, thus closing
contacts Kl-l and energizing stepping
switch solenoid.
3. Simultaneously, the GO light will be
illuminated via comparator contacts
HL-2, LL-2 and relay contacts K2-1.
4. After 1 second contacts Kl-l open, the
stepping switch solenoid becomes de-
energized and the stepping switch moves
to the next position. A tinme delay of
one humdred milliseconds is inserted
between each comparison by using "slow
operate" relays for K2 and K3.
For an unsatisfactory test condition,
the followring is the sequence of events:
1. Relay K2 or K3 will be energized -
assume K2 to be energized.
2. Assuming the tested voltage to be too
high, contacts LL-2 of comparator will
close and the NIO-GO LIGHT will illumi-
nate via contacts K2-1. No other
action would take place and no further
automatic sequencing will occur.
(Correspondingly, the same type of
action would take place in the event
that the tested voltage is too low, ex-
cept that in this case contacts HL-2
would come into play).
Some Additional Design Features of the
Equipnent
It is felt that the following addi-
tional features of the design are worth
discussing:
1. By switching to MANUAL it is possible
to checkout any of the 25 functions in
any desired sequence, repeating any
single test as many times as may be
desired.
2. The automatic checking sequence may be
repeated prior to launch as inany times
as is desired by depressing the HOME
light.
3. The automatic launch sequence may be
aborted manually at any time, even
after the umbilical plugs have been
separated from the drone. (This is
accomplished by energizing a solenoid
coil installed on the launcher close to
the drone skin in the vicinity of a
magnetically actuated reed switch in-
stalled in the drone).
4. The first step in the automatic check-
out sequence is a self check of the
equipment itself.
5. A set of 38 test points are provided
 IEEE TRANSACTIONS ON AEROSPACE-SUPPORT CONFERENCE PROCEDURES
(tapped at carefully selected points)
which can be used to carry out a
certain degree of troubleshooting on
the launcher.
Equipment Reliability and Maintenance
Referring again to Table IV, it is con-
sidered that the number of components have
been kept to an absolute minimum consistent
with the operational objectives. It is
considered that this, rather than
redundant circuits, will be a major con-
tribution to the reliability of the
equiFpment. All components used are, as
far as possible, standard and have been
used in similar or more severe appli-
cations before. This will alleviate not
only the reliability problem but also the
maintenance task. i1.tost of the components
are plug-in units. The functional test
and calibration of the equipment is very
simple, being limited to resistance
checks, voltage checks, relay energization
and measurements of time intervals.
COVCLUSIONS
It is considered that the concepts and
design described prove that it is entirely
feasible to obtain relatively simple, un-
sophisticated automated checkout equipment
using components and equipment well within
present "state of the art" limitations and
yet meeting with such equipment all of the
operational requirements which might be
imposed.
One further conclusion may perhaps be
drawn. The design philosophv adopted is
particularly well suited to acceptance of
frequent system configuration changes
without having to resort to complete
changes in concept but probably limiting
such changes in the checkout and launch
equipment to minor component modifications
and rewiring.
TABLE I
MODULE BASIC FUNCTION
Switching Unit Control of fuel, air and elec-
trical power.
Launch Unit Control of sustainer engine
start and booster ignition.
Checkout Unit Control of checkout function.
Eoming System Functional checkout of dronets
Test Unit homing system.
Control Unit Remote operational control of
checkout and launch sequence.
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TiIBLE II
NFECBSSARY LAUNCHI FUNCTIONS
Supply external power to equipment.
Supply 28V DC to drone for (a) Directional grro
power
(b) iltitude controller
heater.
SupplY 115V 400 cps to drone for directional gyro
erection.
Provide an E. minute ti.le delayr for directional
gyro to erect.
Provide visual and audible signal indicating an
imrmuinent launch.
Supply 28V DC power to drone.
Supaly 28V DC power for the operation of the fuel
supply unit.
Eirovide a means of preventing inadvertant
ig;nit ion.
Actuate launch sequence hy:
(i) Providing 28V DC powier to sustainer torch
igniter valve.
(ii) Providing 28V DC power to starting sir
valves.
(iii) Providing 28V DC power to ignition control.
(iv) l'roviding 28V DC pover to mnain fuel supply
valve after 1 sec. delay.
(v) Providing an cautomatic abort sequence in
the event of sustainer engine not igniting,
or reaching rated temperature or speed.
(vi) Switch power and fuel supplies from
external to internal.
(vii) Elevate drone to launch attitude.
(viii) Release umbilical connectors.
(ix) Provide an abort functiorn even after
release of uabilical.
(x) I'rovide 28V DC booster ignition power for
a predeterrmined period of time.
TABLE III
SELECTED CHECKOUT FUNCTIONS
+14 volts external supply
-14 volts external supply
Payload (camera system)
Homing marker transmitter
Recovery parachute release command
Homing guidance signal (left, centre, right)
Homing sidestep command
Altitude controller
Vertical gyro nulling (pitch, roll)
Autopilot pitch channel (up, centre, down)
Autopilot roll channel (left, centre, right)
Autopilot yaw channel (left, centre, right)
Directional gyro nulling
Sustainer engine jet pipe temperature after
"'light-up"
Sustainer engine idle speed
Sustainer engine jet pipe temperature and
speed at rated speed.
DC power from internal drone power supply
 IEEE TRANSACTIONS ON AEROSPACE-SUPPORT CONFERENCE PROCEDURES

TABLE IV

MiAJOR PARTS DISTRIBUTION

0
0 0 E-

Switch Lights
Solenoid Operated
43
5
2 45
I l-lz
5 AIQ..... r
Switch Lights SOPPLY
FUEL

DPDT Switch 1 SL)PiPL'

1 EQOuIPME,ri=T UNIT ;UIT
Variable Resistor 1 1 2
10 .dafer 25 Position 1 1
Solenoid Operated
Stepping Switch
Single Pole Relay 2 7 9 s>Lv uwtr.
Two Pole Relay 5 7 18 30
Three Pole Relay 1 2 2 5 FIGURE 1
Two Pole Time Delay 3 5 1 9
Relay SIJSPTVJIED SYSTMI SCHEMATIC
Diode 2 2 7 11
Mercury Cell Battery 2 2
Capacitor 2 1 3
Voltage Comparator 2 2
with Two Pole
Outputs
Fixed Value Resistor 44 2 46 MOfl LE~
Four Pole Relay 1 1 2
Single Pole Time 1 7 8
Delay Relay L
Five Pole Relay 1 1 CiFCI:- OUT
Eleven Pole Relay 1 1
Sixtenn Pole Relay 1 1
Three Pole Time 1 1
Delay Relay U) N 17
Voltage Comparator 1 1 Lkulw6{A
with Four Pole IT
Outputs
Push-pull Magnetic- 1 1
Amplifier
D.C. Magnetic 1 1 TO Dt)eOE
Amplifier
Two Phase Circuit 1 1 54ITCHkING T
_-C Pr:C-' TE
Breaker U,NIT UITerc
.%Q
-rc. LEcTS A,.\,
C
Indicator Light I _1 1
FIGURE 2
SYSTEM MIODULAR CONSTRUCTION

543
 IEEE TRANSACTIONS ON AEROSPACE-SUPPORT CONFERENCE PROCEDURES

ACTUATE PRIMARY PWR SWITCH CODE-

--)POWER TO MAG. AMPS. MMANUAL ACTUATION BY OPERATOR
X"POWER ON LIGHT ON EQUIPMENT OUTPUTS
)"EXTERNAL PWR OFF" LIGHT ON > INDICATOR LIGHT ON
^x"AUTOM. CHECKOUT SEQUENCE HOME" LIGHT ON ;;> INCAMTOR LIGHT FLASHES
l-"CHECKOUT SEQUENCE MANUAL" LIGHT ON
ACTUATE" DRONE SELECTOR" SWITCH LIGHT
-L'SELECTED DRONE" LIGHT ON
->POWER TO DIRECTIONAL GYRO ROTOR
i POWER FOR DIRECTIONAL GYRO ERECTION
->POWER FOR ALTITUDE CONTROL HEATER
8 MINS. r
(DIRECTIONAL > DRONE READY"LIGHT ON
GOES

'"EXT PWR ON" LIGHT FLASHES

-OACTUATE"DRONE READY"SWITCH LIGHT
-0|ACTUATE "EXT POWER" SWITCH LIGHT
-->"EXT. POWER ON" LIGHT ON
--'DRONE RELAYS LATCH
4- AUTOM. CHECKOUT SEQUENCE HOMES
I SEC. -
4wWARNING LIGHT FLASHES
>HORN HOWLS
j-'D.C. PWR IS APPLIED TO DRONE
-I-DIRECTIONAL GYRO COMMENCES NULLING
2 MINS. --

I j"AUTOM. CHECKOUT STEP" LIGHT FLASHES

*"ACTUATE"AUTOMATIC" SWITCH LIGHT
! >"AUTOM" LIGHT ON
4|ACTUATE"STEP" SWITCH LIGHT
I"STEP'" LIGHT ON
25 SECS.~
r;;"START LAUNCH"
AUTOM.CHECK OUT
PROCEEDS LUC"FLASHES
-OPERATE "ARMING" KEY
; "A'RMED" LIGHT FLASHES
ACTUATE"START LAUJNCH" SWITCH LIGHT
-,TORCH FUEL
-STARTING AR
- IGNITION
SEC.- -
-"EXT. FUEL ON" LIGHT ON
`MAIN FUEL
5 SECS.--,-H
-'tOMBUSTION" LIGHT ON
10 SECS. I .1
*ENGINE "IDLE LIGHT ON
15 SECS. L _.
i-->FULL FUEL APPLIED
)DRONE ELEVATED TO LAUNCH ATTITUDE
30 SECS -4
"RPM" LIGHT ON
"TEMPERATURE" LIGHT ON
I SEC. [ -j
0 C CHANGE TO INTERNAL FUEL
10 SEC;
1- -CHiANGE TO iWTLRNAL PWR
--PROGRAMMER STARTS
I SEC.
)UMBILICALS RELEASE
ALIMBILICAL RELEASE LIGHT ON
X MILLISECONDS -
.BOOSTER IGNITION
.1 SEC. _
! -|'UMBILICAL CLEAR'-
TOTAL TIME II MINUTES 40 SECONDS LIGHT ON

FIGURE 3 CHECKOUT AND LAUNCH SEURNCE

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IEEE TRANSACTIONS ON AEROSPACE-SUPPORT CONFERENCE PROCEDURES

FIGURE 4 COTiTROL UNIT

FIGURE 5 LAUNCH UNIT

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 IEEE TRANSACTIONS ON AEROSPACE-SUPPORT CONFERENCE PROCEDURES

26tbx.
Ss
WAFEQ C

K:

FIGURE 6 ;,lUTCM.ATIC CL.ECKOUT STEPPING SLQUE1JCE CIRCUIT

"START LAUNCH" LIGHT FLASHES CODE.

I-, Mz FLASHING LIGHT
1I ACTUATE " START LAUNCH* SWITCH LIGHT Cz INDICATING LIGHT ON
--TORCH IGNITER FUEL -) ACTION COMMENCES
I-STARTING
I41GNITION
AIR -I ACTION STOPS
n MANUAL ACTUATION
I SEC+-H m INDICATOR LIGHT EXT.
2Z*"EXTERNAL FUEL ON" LIGHT ON
->STARTING FUEL
5SECS. 1OCCUR DI
w "START LAUNCH" LIGHT OFF
I-4TORCH
IGNITER FUEL OFF
I 14START AIR OFF
--IGNITION OFF
I CE"EXTERNAL FUEL ON" LIGHT OFF
4 SECS.
MAIN FUEL OFF
I 1-2 MINUTES-4
I (RAW FUEL
DRAINAGE)

1- SYSTEM READY FOR LAUNCH

i

FIGURE 7 AUTOMATIC ABORT IN THE EVENT OF "NO COMBUSTION" OCCURRING WITHIN 5 SECONDS AFTER LAUNCH SEQUENCE
INITIATIOrJ

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