Avionics NetworkingCustomer Projects and Case Studies

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The CustomerAirbus is a global leader in aeronautics, space and related services. Airbus offers the most comprehensive range of passenger airliners. Airbus is also a European leader providing tanker, combat, transport and mission aircraft, as well as one of the world’s leading space companies. In helicopters, Airbus provides the most efficient civil and military rotorcraft solutions worldwide.

The ChallengeDealing with numerous different variants of cabin configurationsThe cabin is the Unique Selling Proposition (USP) that distinguishes one airline from another. This means that the cabin equipment can differ significantly from airplane to airplane. The Cabin Intercommunication Data System (CIDS) consists of two redundant host computers, touch panels, handsets and headsets, display and warning panels that are distributed throughout and connected via numerous networks and data buses. The system handles over 80,000 signals and 500 data bus links. The huge amount of system components, signals and communication channels have made tests increasingly more time-intensive. Previous test benches required many manual interventions and operating steps. The system would need to generate all the required stimuli, monitor all outputs and simulate the necessary aircraft environment. It would also need to enable test engineers to create automated test procedures easily and rapidly. One of the most important requirements remained that the test system must permit easy adaptation of the tests for different cabin configurations.

The SolutionStandard Test Package suitable to supplement customer-specific extensionsVector's CANoe software is used as the test and simulation software. CANoe serves as a platform for executing the tests, displaying test reports as well as for implementing the remaining bus simulation and environment simulation for the system under test. The Vector VT System is tailored for this, providing the measurement hardware, interfaces, switching units, etc. In the effort to attain a high level of

test automation and wide-ranging re-usability, it is possible to apply tests that have already been written to any conceivable equipped test benches. This is managed by the Test Auto-mation Framework (TAF). The TAF is located between test case design and the test execution environment, and it can be subdivided into a lower layer, the TAF Core, and an upper layer, which provides test functions. The TAF Core represents the runtime environment for developing test functions and test cases, and it supplies information about the test system and cabin layout. The upper TAF layer provides the test functions and represents the actual interface to the test design.

The AdvantagesSignificant time reduction and high degree of flexibility

> Test benches implemented for the CIDS have led to a significant test time reduction for high-level tests: from one week down to single hours > New systems can handle up to 6,000 input/output channels, and they are distinguished by their high degree of flexibility > The achieved flexibility makes it easy to re-use already written tests for other configurations and product lines

More information: www.avionics-networking.com

System test rig with cabin ceiling, some original equipment, and control desk (Photo: Airbus / Michael Bahlo)

Case Study Airbus Operations

How to Handle Gigantic Testing Tasks with Standard Solutions

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The CustomerAlphaLink Engineering GmbH is a spin-off from Technische Universität Berlin. AlphaLink is specialized in the development and implementation of mechatronic systems. The focus is on the system design of mechatronic systems in aviation, which includes the modeling and control of the entire aircraft, but also of its individual components. With the "Flying Lab" and the "Virtual Flight Test Environment", AlphaLink offers two products in the field of Flight Control for Unmanned Aircraft Systems (UAS).

The ChallengeHardware-in-the-Loop Simulator for PixhawkHardware-in-the-loop simulators (HIL) have been used in manned aviation for a long time to reduce the risk of system failures and pilot errors. A HIL enables testing of the entire system with actuators and displays and training of pilots on aircraft with new flight control systems and/or displays. A variety of solutions for HIL exists for UAS, but a high level of safety is required in aviation. The goal was to establish a toolchain for the most widely used flight control computer, the Pixhawk, to test the system safely with commercial software and hardware that is already used in manned aviation. For this purpose, the Pixhawk ought to be connected to CANoe via a CAN interface.

The SolutionBuilding a digital twin and linking the digital world with the real world via a CAN interfaceTwo main components are needed to build a high-quality HIL:

> a digital twin of the UAS with all its components such as flight dynamics, sensor models, and actuator models, and > a bridge between the digital world and the real existing flight control system (FCS) with all its components, such as data link and remote control.

The digital twin was replicated in a Simulink model. In system identifications, the real behavior of flight dynamics, sensors and actuators were determined and formulated into math-ematical models in Simulink. The Simulink model was linked to CANoe. The Pixhawk has a CAN interface that can be configured for different operating modes. However, a direct connection to CANoe was not possible. Therefore, the Flight-

Stack was modified. In addition, software modules that normally read out the sensors were adapted so that the measurement data like IMU and GPS were replaced by the corresponding CAN messages from CANoe. Commands from the FCS to the actuators are transmitted via CAN messages back to CANoe and thus also to the Simulink model. This allows to simulate a flight with all components. In addition, specific error cases can be implemented. To visualize the flight movement, the Virtual Flight Test Environment is used, which provides a three-dimensional view of the UAS flight in a real environment presented in the web browser.

The AdvantagesReduction of system and human failures in unmanned aviation with a reliable toolchain

> Increase safety for UAS and payload by reducing risks of system failures and human error in real-world operation > Testing with valid state-of-the-art test software and hardware to ensure a high-quality standard of safety > Applicability of the entire concept to any UAS that has a Pixhawk flight control computer > Testing of UAS with conventional drone hardware and software > Training of UAS pilots on aircraft with new flight control systems and/or displays to reduce costs for real flight tests

More information: www.avionics-networking.com

Implementation of the Hardware-in-the-Loop Simulator (Photo: AlphaLink Engineering GmbH)

Case Study AlphaLink Engineering GmbH

Hardware-in-the-Loop Simulator for UAS with Pixhawk FCS

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The CustomerAirbus is the world’s leading commercial aircraft manufac-turer whose customer focus, commercial know-how, tech-nological leadership and manufacturing efficiency have set the standard for the aviation industry. Ensuring the compa-ny’s full range of jetliners remains at the cutting edge of performance, Airbus is continuously developing product innovations to meet its customers’ needs. Airbus’ modern and comprehensive product line comprises highly successful families of aircraft ranging from 100 to more than 500 seats.

The ChallengeReduce time of CAN bus data traffic and signal quality testingThe specific process for developing CAN networks at Airbus requires test and verification procedures. Since the A380 program, continuous enhancements have been imple-mented to execute the test procedures more easily and efficiently. Automated test procedures are a requirement to provide a further reduction in test times.

The SolutionAutomation of test procedures and report generationCANoe with the Scope option, PicoScope oscilloscope hardware and the VN1630 network interface represented the starting point for developing automatic procedures to conduct the following tests:

> LRU physical layer and data layer tests to analyze and evaluate the signal quality > Data traffic tests to verify the CAN traffic against network specification > Live data testing to determine if LRUs are transmitting Tx frames

Data obtained from the testing process are stored in an automatically generated XML file which is then used to seemlessly generate the resultant test report.

The AdvantagesTest time reduced by one-half The customized automatic CAN bus tester reduced the amount of test time by one-half. In some test cases Airbus

was able to realize a reduction in total test time from 8 hours to just 15 minutes, including report generation. The primary reason for this improvement was to set the oscil-loscope’s start trigger automatically for each frame and not manually.The tool is a stand-alone, light-weight and robust test unit that makes it easier to conduct the tests in harsh, cramped and limited spaces in the aircraft. Extensive test reports were automatically generated by CANoe in specified templates and layouts.

More information: www.vector.com/aerospace

Automatic CAN Bus Tester main user interface showing the sum-mary verdict of each LRU

Case Study Airbus

Automatic CAN Bus Tester Significantly Reduces Test Effort

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The CustomerHybrid Air Vehicles (HAV) in Bedfordshire (Great Britain), with over 40 years of experience, is the world’s leading manufacturer of hybrid air vehicles with “lighter than air technology”. It is the owner, designer and producer of the Airlander 10, the world’s largest aircraft. The first flight of the Airlander 10 took place in August 2016.

The ChallengeTesting of the control and communication systemsBefore the first flight, it was necessary to extensively test the control and communication systems of the "Flight Control Network", "Power Distribution Controller" and "Flight Test Equipment." Since there were no proven concepts or examples that already existed, much had to be developed from the ground up.During the flight test program changes will be made to the aircraft. The test system should quickly incorporate these changes and deliver an accurate and updated test environ-ment. Therefore, HAV was looking for a flexible test system. This should not be optimized for a specific purpose, but a general tool for the various tasks related to the avionics developments of the Airlander. Due to the large number of functions to be tested, several hundred test cases had to be run.

The SolutionRealistic HiL tests with CANoe and the VT SystemTo handle its challenging and highly complex tasks as simply as possible, HAV decided on using the tool chain of CANoe, vTESTstudio and the VT System. CANoe is used as a central tool for analyzing, automatically testing and simulating the bus communications of networks and individual LRUs (line-replaceable unit). In addition, it supports such bus systems as AFDX, ARINC 429, ARINC 825 and CAN. The VT System makes it easy to set up test benches and HIL test systems, because it contains all the circuit components for connecting I/O channels. The test cases were created with vTESTstudio.HAV used CANoe to model the entire communications network and simulate artificial pilot inputs to various

systems in order to fully test the Flight Control Network on the ground with the VT system. In addition to this, CANoe was used to create a real-time environment bringing together Matlab/Simulink flight models (including aerodynamics) with real pilot inputs via touchscreens, throttle quadrants and sidesticks to produce a training device that is completely independent of the real aircraft.

The AdvantagesSimplified test processes and 100% test coverageThe development and test processes of LRUs and commu-nication networks for the Airlander 10 were simplified sustainably:

> CANoe, VT System and vTESTstudio offer HAV engineers an optimal tool combination – from HIL testing of indivi-dual LRUs to verification of entire sub-networks. > Early testing without real hardware by simulating hard-ware and software > 100% test coverage by automated test sequences > Rapid creation of test configurations > Traceable test results > Reliable and reproducible simulations and tests

More information: www.vector.com/aerospace

The airlander training device is controlled by panels, which are created individually with CANoe.

Case Study Hybrid Air Vehicles (HAV)

Communication Systems of a Hybrid Airship Successfully Tested

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The CustomerHispano-Suiza is a Centre of Excellence of the SAFRAN Group in the areas of engine control and monitoring systems, electrical and electronic equipment. Hispa-no-Suiza is the global market leader in power transmis-sions for commercial jets. FADEC International LLC, a joint-venture formed by BAE Systems and SAFRAN, is now global market leader in 100+ passenger civil aircraft engine controllers.

The ChallengeIntegrated and optimized systems for tomorrow’s advanced design “more electric engine”Requirements for the “more electric engine” controller needed to be analyzed with regard to the data bus proper-ties. For evaluating CAN and FlexRay, a rapid prototyping and analysis tool chain should be implemented to provide information on timing, reliability, and bandwidth usage under varying conditions.

The SolutionSimulation, analysis and testing with one toolCANoe.FlexRay is used to design a CAN and FlexRay communication system and perform real-time simulations. Analysis with CANoe provides all the timing characteristics of the system. In final evaluation, the same analysis is applied to the real system.

The AdvantagesFast and reliable development and analysis of FlexRay-CAN systems CANoe.FlexRay supports Hispano-Suiza engineers in developing the “more electric” engine controller:

> Simulation setup of several alternative communication designs and flexible parameterization facilitates simulation, testing, and analysis of FlexRay systems > Functional and integration testing of electronic units > Network integration testing > CANoe.FlexRay in gateway operation: Simultaneous stimulation and analysis of CAN and FlexRay networks > Cycle multiplexing, in-cycle multiplexing, signal groups, and sub-frames: well-organized display in analysis windows, flexible use in simulation

More information: www.vector.com/aerospace

CANoe.FlexRay is used to design, simulate, analyze and test a CAN and FlexRay communication system with one tool.

Case Study Hispano-Suiza

Validation of Data Bus Concepts for Aircraft Engine Controller

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The CustomerThe department for Flight System Dynamics at the Technical University of Munich is developing new types of flight control algorithms. In order to test them, the depart-ment owns and operates the DA42M-NG “OE-FSD” – a twin-engine CS-23 research aircraft with an experimental fly-by-wire flight control system. A multi-stage monitoring and safety concept enables safe isolation of the electrical flight controls from the mechanically-reversible flight controls of the safety pilot at all times. This makes it possible to safely test algorithms and sensors in flight and perform experiments in an efficient way.

The ChallengeAnalyze and test the network communication of more than 25 bus nodes on four ARINC 825 data busesThe sensors, flight control computers and actuators are networked via four CAN-based ARINC 825 data buses with more than 25 bus nodes. This results in complex information sharing between the nodes whose timing must be implemented and tested precisely. This is accomplished by detailed analysis of the time behavior of the nodes as well as bus load analysis.It should also be possible to execute a partial startup to perform detailed error analysis. A remaining-bus simulation must be available, which handles the sending of specific configuration messages. Another basic challenge for robust operation in the aircraft is to implement a way to analyze the physical transmission quality of the wire harness under real environmental conditions.

The SolutionReliable and safe operation of the flight control system by aircraft-in-the-loop simulationVector products are used from initial startup of the components in the laboratory to their integration into the aircraft. Combining the CANoe test and analysis tool with Option .Scope and the VN1630A interface assures reliable and safe operation of the flight control system and the system monitoring. As part of an aircraft-in-the-loop simu-lation, this tool combination enables analysis of the total

aircraft and all of its components until just a few minutes before a test flight.One crucial aspect is live acquisition of the entire CAN data stream with high-resolution time stamps in the Trace and Scope views of CANoe. Another is that messages can be dynamically created from CANoe using signal generators and programmable sequences. CANoe offers quick access to all relevant data of the flight control system based on direct interpretation of the user data in the received CAN messages via the stored database.

The AdvantagesQuick startup, graphical evaluations and extensive timing analysesSmart management of the large number of messages and signals in DBC databases facilitates easy evaluation in CANoe. Essential requirements for starting up the system and performing timing analysis include the ability to send complex configuration sequences from CANoe using auto-mated sequences and to produce graphic plots showing flags and signals. Export to Matlab also enables post- processing in the engineer’s own evaluation routines. There-fore the CAN toolchain from Vector provides an open development platform to handle all CAN-related tasks in the laboratory and at the airport.

More information: www.vector.com/aerospace

Working area of a flight test engineer inside the research aircraft

Case Study TU Munich

Startup and Analysis of a Digital Flight Control System

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