Pitot Air Tester Technology: The Latest Trends

There is no room for error when it comes to the air data an aircraft needs to operate safely. From vertical speed to altitude and airspeed, every flight is predicated on the precise measurements coming from the pitot-static system. Given how vital these are, maintenance crews will turn to a pitot air tester or Air Data Test Set (ADTS) to make sure the aircraft’s instruments and sensors are working as they should.

The function these test systems have not changed, but one would be hard pressed to find the same technology in today’s models as there was a few years ago. Current pitot air testers are quicker, more user friendly and accurate, and up to the task of servicing a wide array of platforms. This includes everything from commercial airliners and military hardware to business jets, helicopters and the new breed of eVTOL aircraft.

What follows are the trends that the folks at Avionteq are seeing in the Pitot Air Tester market. 

Advanced Pressure Sensor Technology for Better Accuracy

Any pressure measurement system is at the core of a pitot air tester. A minute error in pressure can become a sizeable inaccuracy in airspeed or altitude, so the quality of the sensor is paramount in an ADTS.

To that end, manufacturers are putting considerable resources into high-performance sensing tech that offers long term stability and little drift. You will find that modern resonant and MEMS-based sensors give operators better repeatability and tighter calibration tolerances. Baker Hughes is a case in point; its Druck ADTS line makes use of proprietary TERPS® (Trench Etched Resonant Pressure Sensor) for a degree of accuracy and stability that also means less frequent recalibration. It is well suited to the demands of RVSM testing as well. In short, the newer pitot testers are evolving into true precision instruments instead of mere pressure generators.

Wireless Operation and Technician Efficiency

It used to be that an aircraft inspection meant technicians were constantly shuttling between the cockpit and the ground cart with hoses in tow. Modern pitot testers have made for a simpler workflow.

With the advent of wireless handheld controllers, a technician can now run the whole test sequence from the cockpit. There is no need for the lengthy cables of old to monitor progress or put down results. For larger aircraft this kind of wireless operation is a boon for safety and flexibility. It trims the setup time and the tangle of cables, and for a maintenance outfit running several inspections a day, those minutes saved add up to better productivity.

The Rise of Automated Test Sequences

Automation is perhaps the most notable change in pitot testing. Where a technician once had to manually work through each verification point for altitude and airspeed, today’s Air Data Test Sets have the ability to store and run an entire profile for a given aircraft.

The equipment can handle leak tests, execute programmed profiles, verify airspeed and log the pass or fail outcome with minimal input from the operator. This not only puts the brakes on human error but ensures a uniform procedure no matter who is on the job. That sort of consistency is worth something to an MRO or airline with a large fleet to look after.

Portable Solutions for the Flightline

Not all maintenance is done in the comfort of a hangar. Inspections are often carried out on the ramp or at remote sites, so manufacturers have been making their pitot testers lighter and more rugged to suit the environment.

A portable Air Data Test Set these days is compact and built to last, with a protective case and the ability to run on battery power for a quick start up. This gives a technician the means to address an Aircraft on Ground (AOG) situation right where it is, rather than having to move the plane into a facility. For operators looking to keep downtime to a minimum, being able to get highly accurate results in the field is a distinct advantage.

More Capable Leak Detection

Then there is the matter of leaks in the pitot-static system, which can throw off instrument readings. Identifying them is a key part of any maintenance regimen, and recent designs of pitot testers are far more adept at spotting even the smallest of pressure losses in short order. With the advent of faster data acquisition, higher-resolution sensors and better pressure control algorithms, technicians are able to find leaks with an efficiency that was not possible with earlier equipment.

Manufacturers have been quick to respond to such needs. Some have put forward handheld leak-testing instruments of their own to go along with the more substantial Air Data Test Sets. With these portable units, a technician can carry out a quick pitot-static test and leave the larger systems for when a full air data evaluation is called for.

Reducing Calibration Downtime

In the past, calibration meant taking pitot testers out of service for long stretches to be sent off to a specialist lab. That is a challenge manufacturers are now tackling by making the process more accessible and expedient. The introduction of new transfer-standard equipment means maintenance groups can do the verification in house instead of depending on outside parties. It is a way to lower costs, get shorter turnarounds and add some flexibility to the maintenance schedule. For aviation organizations intent on operational efficiency, having that kind of in-house capability is hard to resist.

Support for a Wider Range of Aircraft

The modern fleet is far more varied than it was ten years ago. A given maintenance outfit might have on its books regional and commercial airliners, military types, helicopters, cargo and business jets, as well as unmanned systems and the like. There is little point in buying separate gear for every platform; versatile pitot testers are the order of the day. To that end, one will find configurable two-, three- or four-channel systems from manufacturers, with software profiles set up to handle an array of aircraft. It is a flexible approach that lets an organization build out its capabilities without having to replace what it has.

Digital Workflows and Smarter Software

Today’s pitot tester is something of an intelligent diagnostic tool, not merely a pressure generator. The software on hand will have testing libraries for specific aircraft, an interface to walk the technician through an inspection, and the ability to export data for documentation. When it comes to regulatory compliance, digital recordkeeping is superior to the old way of manually noting down each test point. A comprehensive report can be produced right after an inspection is done, which also makes for easier traceability at audit time.

New Sensors and What They Mean for Testing

There is an ongoing cycle where advances in the aircraft itself dictate what is needed on the ground. Researchers are at work on a new breed of miniature pressure sensor that is lighter, more reliable and offers consistent readings. MEMS-based technology in particular is showing promise for its stability and redundancy in all kinds of environments. As these make their way onto future aircraft, the pitot air testers used to check them will have to keep pace.

A Better User Experience

Usability is a trend that is easy to overlook but no less significant. Manufacturers know their technicians have to operate under real world conditions, sometimes outdoors and on a tight schedule. Newer models come with large color touchscreens and streamlined menus to cut down on the training a new hire will need. They start up quickly and have guided procedures to prevent setup mistakes. In fact, ease of use is now almost as much of a consideration as accuracy in the purchase of new equipment.

What to Expect

As aircraft grow in sophistication and the drive for efficiency continues, so too does the technology behind pitot air testers. The Air Data Test Sets available today offer a degree of automation, wireless operation and leak detection that would have been hard to put into words a few years back. One can expect even more in the way of predictive diagnostics and connectivity to come.

For an MRO facility, airline or military operator, putting money into this kind of system is not just about ticking the boxes for regulators. It is a matter of keeping productivity up and aircraft in the air, while ensuring the air data systems the pilots rely on are as accurate as they can be.