Aerospace Project Integration at OPAL-RT

Aerospace Project Integration

Alexandre Leboeuf, Integration Team Leader at OPAL-RT

October 10, 2013

• Systems Integration

– Concept

– OPAL-RT

• Main Components of an Integrated System

• An Aerospace Project Management Process

• OPAL-RT’s Electronic Systems Integration Team

• Success Stories and Other Examples

• Conclusion and Questions

Presentation Outline

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A Little About Myself

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Alexandre Leboeuf

• Electronic Systems Integration Team Leader

• Project Manager

Studies:

• Bachelors degree in electrical engineering at École de technologie supérieure (ÉTS)

with a minor in health care technologies.

• Technical degree as a programmer

OPAL-RT TECHNOLOGIES and me:

• Internships in 2008 and 2009

• End of studies project with Opal-RT in 2010

• Started officially in 2010

• Created the electronic systems integration team in 2011

Wikipedia defines systems integration as :

“the process of bringing together the component subsystems into one system and

ensuring that the subsystems function together as a system.”1

Key concepts:

– Bring together 2 or more subsystems into one complete system;

– Subsystems function together as whole.

Subsystems:

– A set of elements, which is a system itself, and a component of a larger system. Be

it software, hardware or a combination of both.

Systems Integration – A Concept in a nutshell

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1. http://en.wikipedia.org/wiki/Systems_integration - Consulted on 10/08/2013

• The integration of a real-time simulator and its components is a hard and complex

process.

• Components may not even be part of the customer’s or OPAL-RT’s product line-up.

• Each customer has his own specific set of requirements. Unique case circumstances.

• Customer’s time should be more focused his core business.

So what can be offered to facilitate each and every step? What can be adapted to each and

every need?

No product can offer all solutions...

Systems Integration – OPAL-RT’s Understanding

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No product can offer all solutions. No indeed.

But a package of products (subsystems) working together would solve those problems.

Which brings the Turnkey RCP/HIL simulator solution.

Turnkey solutions in systems integration would:

• Support the unique needs, unique solutions required.

• Provide complex systems in really short time frames. (12 to 18 weeks)

• Allow the customer’s time to be focused on what matters most.

Systems Integration – OPAL-RT’s Response: Turnkey Solutions

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Systems Integration – OPAL-RT’s Response: Turnkey Solutions

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2 approaches are available:

• Full modular design that supports easy upgrades, has space for added needs. (More

horizontal design approach)

• Completely specialized equipment with no room for upgrade. (More vertical design

approach)

Each has its merits and downsides.

In the end it all comes to your needs:

• Real-Time requirement? Time Step?

• Setup might change frequently?

• Test automation to save on time?

Components

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Typical RCP Configuration:

• Host Computer (Host)

• Target Computer (Target)

• Models

• Human Machine Interface (HMI)

Typical 1 Controller HIL Configuration:

• Host Computer (Host)

• Target Computer (Target)

• Interconnection Box (Mapping Unit)

• Break-out Box (BOB)

• Fault Insertion Unit (FIU)

• Load Box

• Control Unit (UUT)

• Models

• Human Machine Interface (HMI)

Components

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Components

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Real-time Simulator (OP5600)

Purpose:

Does the real-time computation and the

acquisition over the different I/Os.

Characteristics:

• Has 8 I/O slots

• Supports PCI and PCIe card

• Offers front monitoring

• 4U form factor

• Spartan3 or Virtex6 FPGA options

• Other simulators models available as well

Interconnection Box (Mapping Unit)

Purpose:

Adds a conditioning layer to the I/Os and

routs all signals throughout the system.

Characteristics:

• Made from off-the-shelf components

• Custom made to fit every project

• Comes in 2U and 4U format

Components

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Components

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Components

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Break-out Box (BOB)

Purpose:

Manually monitor signals, reroute signals,

create shorts, and open circuits.

Characteristics:

• Up to 104 low current circuits (1, 3, 5, 8 amp)

• Separate plug in modules (Group of 8)

• Up to 18 high current circuits(10, 15, 20 amp)

• 3U form factor

Components

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Fault Insertion Unit (FIU)

Purpose:

Automatically insert faults during simulation.

Faults include shorts to ground, short to

battery, short between 2 signals, add inline

resistance and open circuits.

Characteristics:

• Supports up to 10A per channel

• Multiple configuration (32, 96, and 120 ch.)

• 3U form factor

Components

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Load Box

Purpose:

Add easily swappable load drawer.

Caracteristics:

• Made from off-the-shelf components

• Use of real or simulated loads

• Custom made to fit every project

• Comes in 2U and 4U format

Components

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Rack

Purpose:

Hold full solution in one easy movable bay.

Characteristics:

• Made from off-the-shelf components

• Reinforced wheels for heavy load easy

movement

• Comes in 24U and 40U format

Components

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Control Unit (UUT)

Purpose:

To be defined.

Characteristics:

• Your own design

[INSERT YOUR

DESIGN

HERE]

Components

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Models

Purpose:

Create the simulated environment.

Characteristics:

• Interfaces with I/Os

• Contains your equations for the simulation

• Built in MATLAB Simulink

• May contain C coded S-Functions

• Controls the FIU and other subsystems

• Once compiled runs in real-time under RT-

LAB

Components

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Human Machine Interface (HMI)

Purpose:

To monitor and control the simulation.

Characteristics:

• Used to automated testing of UUT

• Easily observe what is going on with gauges

and indicators

Components

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Communications Protocols

Purpose:

Communication between aircrafts subsystems

Characteristics:

• Multitude of standard protocols supported

• MIL-1553, ARINC429, CAN, AFDX

(coming)

• Capacity to create driver for new and

specific applications

OPAL-RT TECHNOLOGIES’ process:

• Based on the aerospace project management model.

• Adapted to retain critical milestones while adding more flexibility.

• Developed with aerospace customers for aerospace customers.

• Defines a clear design to delivery time line that typically is between 12 to 18 weeks

from PO to shipping.

• Involves the customer at each step.

• Certified ISO 9001:2008 since 2012.

From Imagination to Real Time – A Project Management Process

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• RFQ

• Quote

• PO

• Design Process

– KOM

– PDR

– CDR

– Production

– Factory Acceptance Tests

– UUT Integration

– Delivery

• Commissioning / Training

• Support

A Project Management Process – Steps Overview

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What is necessary for us as output of this phase:

– Complete spec of the hardware to interface (mechanical drawings, circuit examples, signal

types and spec.)

– Signal List

– Sketch of HMI or list of functionality required

– Required delivery date of system

– Availability for questions and 1 meeting to set the project into perspective

– Time (between 1 week to 2)

NDA can be signed without problems to ensure secrets of the trade.

Usually at this stage, the customer is alone, but OPAL-RT offers tools to help build the

technical specifications that will be used to design the turnkey solution.

A Project Management Process - RFQ

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Examples of template we offer:

• PFXXX-XXX_EICD_Electical_Interface_Control_Document_Rev1.0_TEMPLATE

– Excel which contains the list and specs of each signals.

• PFXXX-XXX_SICD_Software_Interface_Control_Document_Rev1.0_TEMPLATE

– Excel which contains the list of signals required on the HMI.

A Project Management Process - RFQ

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A Project Management Process – Quote and PO

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Quote Example:

A Project Management Process – Quote and PO

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Along with the quote, you get: (Hardware Overview, Cabinet Configuration)

A Project Management Process – Quote and PO

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Along with the quote, you get: (Hardware Overview, Target Configuration)

A Project Management Process – Quote and PO

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Along with the quote, you get: (Signal and Connection Overview)

A Project Management Process – Design Overview

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A Project Management Process – Preliminary Design Phase

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A Project Management Process – Critical Design Phase

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A Project Management Process – Production Phase

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A Project Management Process – Completion Phase

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A Project Management Process – Delivery Phase

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• Commissioning (optional but strongly recommended)

– Installation

– On site FAT

– Integration with UUT (If not already done)

• Training (optional but strongly recommended)

– Provide training on the software

– Provide hands on experience on the turnkey HIL solution

• Support

– Help with turnkey HIL solution

– Help integrating environmental models

– RMAs

• Trial started in December 2011 as to see if creating a dedicated team would be viable

and also practical. The trial was made with one team member.

• Officially created in March 2012 with two team members.

• In July 2012, the team got a third team member.

• Now:

– 3 team members

– Team based in OPAL-RT Headquarters in Montreal Canada

– Designed around 25 projects up to now

OPAL-RT’s Electronic Systems Integration Team

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The team is supported by:

• Sales team

– Team of 20 salesman world wide (3 based directly in India)

• Research and Development

– Hardware Team composed of 8 individuals, designs the new hardware or help understanding

really precise hardware system. All based in Montreal.

– Software Team composed of 40 individuals, designs RT-LAB, other OPAL-RT softwares,

drivers for new boards, etc. All based in Montreal.

• Production and Assembly

– Team of 8 based in Montreal. They build our designs.

• Customer Support

– 3 teams that train, do commissioning, support directly the customers. 1 team is based in

Bangalore and is now at 3 members.

OPAL-RT’s Electronic Systems Integration Team

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Success Stories

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Liebherr Canada

Success Stories

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Liebherr Canada

Success Stories

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Some other systems built:

Conclusion

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We presented a short introduction to the systems integration in general based on how

OPAL-RT sees and manages those specific types of projects.

It is a complex environment in which to navigate and the options are numerous, it is really

easy to fall for a certain solution that might not be fulfilling your needs. Your needs should

always drive you.

Typical Applications in which systems integration applies:

– Air Management and Wing Anti-Icing Systems

– Auxiliary Power Units (APU)

– Auto-pilot System

– Satellite Positioning System

– Landing Gear System

– Flight Simulator Core Computing for Pilot Training

– More-Electric Aircraft and All-Electric Ships

Final Words

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Questions ?

CONTACT US: 514-935-2323 – info@opal-rt.com