Engineering expertise for helicopter health monitoring and vibration analysis

Helitune’s engineering heritage dates back to the early 1980s, including the development of the world’s first microprocessor-based rotor track and balance (RTB) system. This pioneering work laid the foundations for Helitune’s long-standing leadership in helicopter vibration monitoring and health monitoring systems.

Today, Helitune is recognised for designing and developing advanced health monitoring solutions for rotorcraft, combining expertise across sensor development, software engineering, data science and systems integration. Our engineering teams focus on solving real-world operational challenges through customer-driven research and development, innovative technology, and deep application knowledge.

A multidisciplinary global engineering team

Helitune’s engineering capability is delivered by a multidisciplinary team of approximately 40 engineers operating across the United Kingdom, Germany and the United States. The team supports core product development activities spanning hardware, software and systems design, working closely to deliver fully integrated monitoring solutions.

Key areas of technical expertise include digital signal processing, data analysis, and airborne systems integration, ensuring Helitune products perform reliably in demanding helicopter operating environments.

All products are developed in accordance with AS9100 quality assurance requirements and conform to the appropriate DO-178 (software) and DO-254 (hardware) design assurance levels.

Advancing data intelligence in health monitoring

Recognising the growing importance of data intelligence in aviation, Helitune established its Data Science Research Group in 2005. This capability plays a central role in enhancing the intelligence of modern health monitoring systems, enabling earlier detection of issues and more informed maintenance decisions.

A key contributor to the success of this work is Helitune’s long-standing collaboration with the University of Bristol, which began in 2006 through an award-winning Knowledge Transfer Partnership (KTP). This partnership has supported the application of advanced analytics and research insight into operational helicopter monitoring systems.

Shaping the future of intelligent monitoring systems

Helitune’s engineers continue to push health monitoring into a new era, developing systems that are increasingly capable of interpreting data, identifying patterns and supporting the right action at the right time and in the right area. This engineering-led approach underpins Helitune’s commitment to delivering smarter, more responsive monitoring solutions for helicopter operators worldwide.

How to contact Helitune

Need technical support, product advice or help choosing the right solution? Our team is here to help and will direct your enquiry to the right specialist.

Phone: +44 (0)1805 626 697
Email the Helitune team for direct enquiries
Availability: Monday to Friday, 9 am – 5 pm (UK time)

Contact Helitune

Calibration and repair services for rotor track, balance and vibration monitoring systems

Helitune provides comprehensive calibration, repair and maintenance services for rotor track and balance (RTB) and vibration monitoring systems. Our authorised facilities in the UK, USA, France and Germany are staffed by qualified technicians with extensive experience in the inspection, repair and calibration of Helitune equipment.

Why calibration matters

The importance of regular calibration

High-precision measuring equipment used in helicopter vibration monitoring and RTB applications should be subject to regular calibration to ensure accuracy and reliability. Industry best practice recommends annual calibration checks, or more frequently where required by the manufacturer or operational environment.

Because Helitune systems are used to assess the condition and performance of aircraft, maintaining calibration accuracy is essential to ensure reliable data and informed maintenance decisions.

Return-to-factory service

Return-to-factory calibration and repair

Helitune offers a return-to-factory calibration and repair service for all Helitune RTB and vibration monitoring systems. Returning equipment to an authorised Helitune facility allows full functional testing, inspection and calibration to be carried out in a controlled environment using approved procedures and equipment.

As an AS9100 Rev D–approved organisation, Helitune follows recognised aviation best practice and recommends that all RTB equipment and associated accelerometers undergo annual calibration by Helitune or an approved Helitune service centre. Failure to follow recommended servicing intervals may result in reduced system performance or inaccurate measurements.

Closed-loop system check 

System-level functional checks

To maintain the highest possible system performance, Helitune recommends that all components within the Rotortuner kit—including cables, junction boxes and peripheral items- are returned for calibration at the same time as the main units.

This closed-loop approach enables system-level functional checks to be completed, helping to reduce the risk of peripheral component failure during operation and ensuring the complete monitoring system performs as intended.

Support and maintenance packages 

For customers with an annual Helitune Support and Maintenance package, routine calibration is included alongside technical support via telephone or email. Packages can also be extended to include on-site support visits, providing additional operational assistance where required.

For further information on calibration services or support packages, please contact the Helitune team.

How to contact Helitune

Need technical support, product advice or help choosing the right solution? Our team is here to help and will direct your enquiry to the right specialist.

Phone: +44 (0)1805 626 697
Email the Helitune team for direct enquiries
Availability: Monday to Friday, 9 am – 5 pm (UK time)

Contact Helitune

Data science for helicopter health monitoring and vibration analysis

Helitune’s Data Science capability focuses on enhancing the intelligence of helicopter health monitoring, vibration monitoring and rotor track and balance (RTB) systems. By applying advanced mathematical and algorithmic techniques, we help operators extract meaningful insight from complex data—supporting informed decision-making and timely, effective maintenance action.

Advanced analytics applied to real-world operations

Established in 2005, Helitune’s Data Science Team works at the intersection of engineering, mathematics and operational aviation. Our specialists routinely analyse live field data from helicopter fleets to identify patterns, behaviours and early indicators of developing issues that are not visible using conventional analysis methods.

This work underpins Helitune’s broader approach to condition-based maintenance, enabling earlier intervention, improved reliability and reduced unplanned downtime across demanding operational environments.

Core data science and analytical capabilities

Helitune’s data science and analytics work draws on a wide range of tools and techniques, including:

• Python and R
• SQL and NoSQL database querying
• MATLAB and Simulink
• Statistical modelling
• Real-time and large-scale data analytics
• Data mining and feature extraction
• Fuzzy logic techniques
• Neural networks and machine learning
• Data visualisation for operational insight

These capabilities support the development of intelligent health monitoring algorithms and decision-support tools used across Helitune’s vibration monitoring and RTB solutions.

Supporting products, engineering and applications

Helitune’s data science capability supports the development of advanced health monitoring systems across our products, engineering, and applications teams—ensuring analytical insight is translated into practical, operational value.

How to contact Helitune

Need technical support, product advice or help choosing the right solution? Our team is here to help and will direct your enquiry to the right specialist.

Phone: +44 (0)1805 626 697
Email the Helitune team for direct enquiries
Availability: Monday to Friday, 9 am – 5 pm (UK time)

Contact Helitune

Maintenance and support packages

Flexible support for Rotortuner systems

Helitune offers a comprehensive range of maintenance and support packages designed to help operators get the most from their Rotortuner rotor track and balance and vibration monitoring systems throughout their operational life.

Our packages are structured to provide reliable, predictable support—whether you require essential spares coverage or a fully managed lifecycle service.

What our maintenance and support packages include

To best support Rotortuner equipment in operational environments, Helitune offers packages ranging from basic spares provision through to full Life Cycle Management, which can include:

• Repairs and functional checks
• Calibration services
• Software and hardware upgrade programmes
• Structured training for system users and managers
• Ongoing technical support via phone or email
• Optional on-site support visits

Packages are tailored to system configuration, aircraft type and operational requirements, ensuring appropriate support without unnecessary cost.

Lifecycle management and long-term value

Helitune maintenance and support packages are designed to support condition-based maintenance, improve system reliability, and reduce unplanned downtime. By combining calibration, upgrades and expert technical support into a single package, operators benefit from consistent system performance and clearer long-term cost control.

Finance and tailored options

To support planning and budgeting, tailored finance options are available across Helitune maintenance and support packages. Our team will work with you to define a package that aligns with operational needs and commercial priorities.

How to contact Helitune

Need technical support, product advice or help choosing the right solution? Our team is here to help and will direct your enquiry to the right specialist.

Phone: +44 (0)1805 626 697
Email the Helitune team for direct enquiries
Availability: Monday to Friday, 9 am – 5 pm (UK time)

Contact Helitune

Mechanical design and aircraft integration expertise

Helitune’s Mechanical Systems Team is responsible for the design, development and integration of vibration monitoring and rotor track and balance (RTB) equipment onto helicopter platforms. Working closely with hardware, software and systems engineers, the team ensures that Helitune products are robust, reliable and suitable for operation in demanding aviation environments.

Engineering design for real-world aviation conditions

Using advanced computer-aided design and simulation tools, mechanical components such as brackets, equipment housings and sensor mounts are modelled, analysed and optimised before manufacture. Designs are then subjected to extensive environmental and structural testing to ensure compliance with civil and military aerospace design and safety standards.

This rigorous approach supports safe aircraft integration and long-term reliability across a wide range of helicopter applications.

Core mechanical design and test capabilities

Helitune’s mechanical engineering capability includes:

• 3D computer-aided design (CAD)
• Finite element analysis (FEA)
• Equipment and electronics housings
• Sensor and mounting design
• Cable and cable harness design
• Bracket and structural design
• Structural design and safety analysis
  (RTCA DO-160G, SAE ARP4754)
• Rapid prototyping using SLA and SLS technologies

These capabilities support the development of mechanically robust systems that protect sensitive instrumentation and ensure accurate vibration measurement in operational helicopter environments.

Supporting integrated monitoring systems

Helitune’s mechanical systems engineering plays a critical role in enabling the reliable deployment of helicopter vibration monitoring, RTB and health monitoring systems, supporting consistent data capture, safe installation and ease of maintenance throughout the system lifecycle.

How to contact Helitune

Need technical support, product advice or help choosing the right solution? Our team is here to help and will direct your enquiry to the right specialist.

Phone: +44 (0)1805 626 697
Email the Helitune team for direct enquiries
Availability: Monday to Friday, 9 am – 5 pm (UK time)

Contact Helitune