How we engineered safer, more reliable control on the ATLAS aircraft loader
This programme reflects our core strengths: multidisciplinary control engineering, deep practical awareness of operating environments, and the ability to deliver one solution that spans mixed fleets. By owning electronics, firmware and integration, we removed friction between disciplines and delivered a safer, more reliable loader – without forcing disruptive fleet changes.
If you operate equipment in safety-critical zones – or need one controller to tame a mixed fleet – we can help. Talk to us about custom ECUs, CAN integration and actuator strategies that reduce risk and standardise behaviour across generations.
AMSS (now part of Oshkosh AeroTech) needed a control system for the ATLAS loader that would manage throttle response and braking with absolute reliability. Operating inches from valuable airframes, the cost of failure wasn’t just downtime – it was potential catastrophic damage. The brief asked for a robust, production-ready ECU that could control brake solenoids, monitor and constrain engine revs within a safe envelope, and interface cleanly with both newer CAN-based engines and older, mechanically actuated variants.
We designed and built the TAD-650, a custom control PCB housed in an IP67 Cinch ModICE enclosure. The unit monitors engine speed and actively controls brake solenoids, ensuring operations remain within defined safety zones during approach and lift. On modern ATLAS loaders, the TAD-650 communicated directly with the CAN-based engine for precise, software-defined control. On older loaders that retained Bowden-cable throttle, we engineered a CAN-controlled actuator to deliver the same predictable response and remove variability from manual throttle inputs.
Control algorithms were tuned for stable RPM windows and repeatable brake behaviour, prioritising deterministic responses over operator finesse. By removing manual variability, the system narrows the range of possible outcomes and materially reduces risk at the aircraft interface.
The ModICE housing, sealed connectors and robust PCB design protect against moisture ingress, vibration and temperature extremes. Harnessing and service access were specified with maintainers in mind – fast swap-outs, clear labelling and minimal disruption during checks.
We treated manufacturability as a first-order requirement, documenting the full stack and validating under representative ramp conditions. That approach compressed the path from engineering sample to repeatable builds and simplified support over time.
The upgraded ATLAS loaders now approach aircraft with calmer, more predictable dynamics. Brake solenoids engage with consistent timing; engine revs stay inside a tightly defined zone; and the transition from approach to lift is smoother and safer. Operationally, supervisors report fewer interventions, and technicians benefit from a sealed, serviceable controller with clear diagnostics and straightforward replacement procedures. For fleet manager running mixed generations, the single ECU strategy is a practical win: one control philosophy, two integration modes, common spares and training.
By engineering out manual throttle/brake variability and hardening the electronics for the environment, the risk profile has improved where it matters most – right next to aircraft. The solution also positions the platform for the future: CAN integration for new loaders and a controlled migration path for legacy units without forcing premature retirement.
Airport ramps are unforgiving: temperature swings, moisture, vibration and constant stop-start duty. The system had to perform consistently despite environmental stresses, and it had to reduce reliance on human judgement where conditions are busy and high-pressure. Compatibility was another hurdle – AMSS operated mixed fleets, so the ECU needed to talk natively to CAN-controlled engines while also replacing manual throttle on legacy machines with a precise, CAN-controlled actuator. All of this had to be packaged in a sealed form factor, easily serviced and resilient to corrosive agents commonly found airside.
The upgraded ATLAS loaders now approach aircraft with calmer, more predictable dynamics. Brake solenoids engage with consistent timing; engine revs stay inside a tightly defined zone; and the transition from approach to lift is smoother and safer. Operationally, supervisors report fewer interventions, and technicians benefit from a sealed, serviceable controller with clear diagnostics and straightforward replacement procedures. For fleet manager running mixed generations, the single ECU strategy is a practical win: one control philosophy, two integration modes, common spares and training.
By engineering out manual throttle/brake variability and hardening the electronics for the environment, the risk profile has improved where it matters most – right next to aircraft. The solution also positions the platform for the future: CAN integration for new loaders and a controlled migration path for legacy units without forcing premature retirement.