open standard signal conditioning in hil simulation · analog, digital, etc. signals adjusted to...

COMPANY UNCLASSIFIED | NOT EXPORT CONTROLLED | NOT CLASSIFIED

Anders Tunströmer| © Saab

Simulator Hardware Department

OPEN STANDARD SIGNAL CONDITIONING IN HIL SIMULATION

Anders Tunströ[email protected]



SAAB AERONAUTICS

2

~3000 employeesGripen Fighter

T-X Trainer(Coorporation with Boeing)

©2017THE BOEING COMPANY © Saab AB



SIMULATORS USED IN ALL LIFE-CYCLE PHASES

3



WHY IS A DEVELOPMENT SIMULATOR NEEDED?

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• Verify Air-worthiness before flight

• Perform tests that are too dangerous to perform flying.

‒ E.g. Inserting failures in the system.

• Capability and availability.

‒ Enormous amount of verification and validation can be performed in the simulators

• Readiness

‒ Tests can be performed with partial system functionality and partial access to real system equipment.

© Saab AB



VERIFICATION COST

5



SYSTEM RIG

Pag

e 6

DUTDUT

ACSim simulationModels of physical

systems

Operator & Pilot

stationInterface to

Operator and Pilot CockpitDisplays

HOTAS

Controls

DUT

Adapter

UnitI/O&Power

Adapter

UnitI/O&Power

Aircraft

Equipment(Device

Under Test)

Aircraft

Equipment(Device

Under Test)

Aircraft

Equipment(Device

Under Test)

Aircraft

Equipment(Device

Under Test)

Aircraft

Equipment(Device

Under Test)

Adapter

UnitI/O&Power

Adapter

UnitI/O&Power

Adapter

UnitI/O&Power

Adapter

UnitI/O&Power

Purpose: Verification of Avionics System integration and functionality.

Flight Safety Test before A/C ground and flight tests

Structure: Complete (or near complete) equipment suite of equipment (avionics), aircraft specific integration (cabling) and simulated aircraft system

A/C specific cabling © Saab AB



AIRCRAFT VS. SIMULATOR

7

Aircraft Simulator

Requirements defined by aircraft Requirements defined by aircraft and additional simulator requirements

Adapter

Unit #1

Eq #1 Eq #3

Eq #2

Adapter

Unit #2

Eq #1

Eq #2

Simulation

Computers



WHAT IS AN ADAPTER UNIT (AU)

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• All things needed to connect an ECU to the simulator.

• ECU = LRU = DUT = …

• 19” rack mounted.

• Including:

‒ I/O-system

‒ Cables

‒ Patch panels

‒ Power supply and monitoring

‒ Tray for ECU

‒ Cooling installation

© Saab AB



SIGNAL FROM MODEL TO ECU EXAMPLE

9

Ethernet

Analog,

Digital, etc.

Signals

adjusted to

match ECU

interfaceSW model

simulationECU

SLSC-chassis

(No real time

support)

National

Instruments

HW (cRIO, PXI)

(Real-time

support)

©

Natio

nal In

stru

ments



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CUSTOM

Today’s Hardware in the Loop System

ECU Connectivity Switches, Loads, and

Signal Conditioning

RT Processing

and DAQ

COTS

Future Hardware in the Loop System

ECU Connectivity Switches, Loads, and

Signal Conditioning

RT Processing

and DAQ



HIL SIMULATION CHALLANGE

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All ECUs (Aircraft units) have their specific need of stimulation.

Time plans.

Long life cycles (>25years).

Government regulations.

Documentation and traceability.

© Saab AB



B787

Next MilitaryVehicle

Unaffordable!

F-35~9.5 Million SLOC~17 yrs. Start->EISGAO-12-437 page 18 6/2012

F/A-18

F-22

F-16F-14

B-2

A-10

THE UNAFFORDABLE TREND FOR AIRCRAFT SYSTEMS COMPLEXITY AND COST OF DEVELOPMENT

Time/Cost

Complexity/SLOC

S/W Integration Dominant

H/WDominant

B737

B777

A300/B747

A320

A340

A380

NextMilitary VehiclePossible!

B787~10 Million SLOC~7 yrs. start->EISBoeing quoted in NYC Aviation, 9/28/2011

SLOC = Source lines of code

EIS = Entry Into Service



HISTORIC HIL SOLUTION STRATEGY

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Everything was custom made in-house architecture.

Built from low-level components.

Vague working processes.

Every HIL simulation was a new design.

© Saab AB



CURRENT HIL SOLUTION STRATEGY

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Apply to Open Standards that enable use of commercial solutions (COTS)

Open standards and commercial solutions enables us focus on core competencies and buy products and general competencies.

Efficient working processes necessary.

Product line approach - Design once and fix once

© Saab AB



ADVANTAGES OF OPEN STANDARDS AND COMMERCIAL SOLUTIONS

• Not limited to specific manufacturers.

• Available to buy on the market.

• Short lead times.

• Specifications are ready and written.

• Update and obsolescence are handle by someone else.

• Training and education available from 3rd party

• Trained consultants available

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AVAILABLE COMMERCIAL SOLUTIONS

• Cables/Connectors

• 1553 Bus equipment

• Hardware for I/O-system

• Signal conditioning (For commonly used signal types)

• RF-articles

• Power supplies

• Synchronization systems

• Rack/Cabinet and accessories

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WHERE COMMERCIAL SOLUTIONS CAN’T BE USED

• Cables to/from ECU (exceptions occur)

• ECU Tray

• Patch panels

• I/O-system software

• Equipment to puzzle all COTS together

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SLSC FROM NATIONAL INSTRUMENTS

• 5U (222mm) height and 19” rack mounting.

• 12 slots for modules

• Modules for signal conditioning, loads, etc.

• Cooling air inlet below the modules.

18

Fan

Vent

½ U

½ U

4 U

Vent

© National Instruments




SLSC OVERVIEW

19

NI PXI/CompactRIO

Pa

tch

panel

To ECUTo Measurement

Hardware




SLSC SYSTEM INCLUDES

Only from National Instruments:

• cRIO/PXI for real-time simulation

• SLSC Chassis

Open standard parts: (from National Instruments, 3rd party or custom solution)

• Cables to cRIO/PXI system

• Cables to Patch panel

• RTIs

• Modules

20

© N

atio

nal In

stru

ments

© Saab AB




SLSC MDK DEFINES THE SYSTEM

• MDK = Module development kit Instructions, guidelines and rules for modules and RTIs.

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OPPORTUNITIES USING COMMERCIAL SOLUTIONS

• With the open standard modules and accesories pops upfrom various companies.

• Develop your own module(s), RTI(s), cables, etc.

• If you find a new need maybe somebody already has the solution or maybe want to solve your issue and sell it on the whole market.

• Mix as you like with equipment from different vendors.

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PARTNERS

• In this case a development partner.

• When commercial solutions and open standards areused the opportunity to use partners increases rapidly.

• Use your established partner or find a new expert in a specific area.

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EXAMPLE: PROBLEM – LIMITATION - SOLUTION

• Problem: Need of reading VDT sensors

• Limitation: Time and personnel

• Solution: Use the SLSC open standard concept and a partner

25

=!?? +

Partner

&

© Saab AB

©

Natio

nal In

stru

ments



EXAMPLE: THE SPECIFICATION

• With only 19 requirements, one block diagram and onegraph our partner managed to design a module that fit ourneeds.

• The SLSC MDK defines the base of the modules.

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ADVANTAGES TO USE ESTABLISHED PARTNER

• Located nearby, meetings face-by-face is easy to manage.

• Short delivery time.

• Working process is established and partner know yourneeds.

• Contracts and agreements signed already.

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THE FUTURE FOR HIL SIMULATION

• Commercial solutions

• Open standards

• Design once

• Optimized working processes

• Aerospace and Automotive cooperation

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Anders Tunströ[email protected]

open standard signal conditioning in hil simulation · analog, digital, etc. signals adjusted to...

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