Simulation through - ADI | Solutions in Real Time

Achieving Software Validation Through Simulation -- Loren Slafer

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"BSS’ spacecraft developmentprocess has..."

Agenda

Satellites in GeosynchronousOrbit

Boeing Satellite SystemsCommercialProductDevelopmentHistory

BSS Heritage for GovernmentPrograms

BSS Satellite Flight Software is Integrated into a SpacecraftControl Processor

BSS’ Spacecraft Risk Mitigation Strategy

BSS’ Standard Approach forSpacecraft Design Validation

Achieving

Software

Validation

through

Simulation

ADIUS 2001

Loren SlaferBoeing Satellite Systems

file:///K|/2000-2001/Int_Exp/1keyslaf.htm (1 of 8)3/11/2005 3:16:26 PMFrom the 2001 Applied Dynamics Intl. ADIUS user conference proceedings


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Synopsis

• BSS’ spacecraft development processhas evolved over 40 years into

» Integrated attitude control subsystemdevelopment process supporting allphases of spacecraft development withIV&V structure

» Common process for all Government andCommercial programs

High fidelity real time simulation-basedtesting has become BSS’ principal

laboratory and proving ground:

Provides validation and verification ofsystem design and performance

Provides invaluable insight into as-builtsystem operations/performance

characteristics

• Process has proven to be significant riskmitigation at BSS

» Leading to successful missionperformance on all past Commercial andGovernment programs

» Currently on-going on all new spacecraftdevelopments

file:///K|/2000-2001/Int_Exp/1keyslaf.htm (1 of 8)3/11/2005 3:18:04 PM


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Agenda

• Review BSS’ standard simulation-based Integrated Development &Validation Process (‘IDVP’)

» Approach & heritage» Risk mitigation strategy for Boeing

spacecraft and software development» BSS approach to spacecraft design

validation

• Define simulation activitiessupporting IDVP activities

• Provide review of the IDVPsimulation elements andapplications

» High fidelity simulation architecture» Simulation-based hardware and software

test systems» Simulation-based validation activities

• Concluding Remarks



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Satellites in Geosynchronous Orbit



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Boeing Satellite Systems Commercial ProductDevelopment History



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BSS Heritage for Government Programs

Navy UHF F/O• 10 satellites – DIO• UHF• EHF• Global broadcast• FFP

NASA GOES N-Q• 2 satellites - DIO• 2 option satellites• Instruments and

communications• Ground station

upgrade• FFP

NASA Trackingand Data Relay

• 3 satellites• Ground station

upgrade• S, Ku, Ka bands• FFP

CLASSIFIED PROGRAMS



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BSS Satellite Flight Software is Integrated into aSpacecraft Control Processor

SENSORS ELECTRONICS ACTUATORS S/C DYNAMICS

Spacecraft ControlProcessor

Spacecraft attitude and rate



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• Development, verification and validation of ACSdesign, Spacecraft Control Processor hardwareand software, and Ground Segment tools criticalto mission success

• To reduce mission risk and ensure spacecraftsafety BSS’ standard practice and processcreates a high fidelity simulation environment tosupport all phases of Spacecraft and GroundSegment development

BSS’ Management Directive:Create a high fidelity simulation environment to let us

‘Fly the spacecraft on the ground’Mixed Simulation Testing



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BSS’ Standard Approach for Spacecraft DesignValidation

(Test Environments Common to all Government & Commercial Programs)

SharedSpacecraftValidationActivities

‘Pure’ Simulation & Mixed SimulationTesting

Precisely controlled, simulated on-orbitenvironment using flight-like SCP for ACS designV&V - Develop on-orbit performance predictions

Flight software development & qualification; flightSCP unit level acceptance test

Integrate and early test of Ground Softwareenvironment - confirm space/ground interfaces

High fidelity, closed-loop real-time spacecraftsimulation which integrates the flight SCP

Verify Mission design/plan, Customer training

Verify all spacecraft operational procedures



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System Test Independently Validates allFunctions and External Interfaces

• Independent System test team validateall interfaces to actual spacecraftcomponents using ACE flight hardwareand software, TT&C, and GOES NGTACS ground software

» ADCS sensors and actuators (star trackers, sunand earth sensors, reaction wheels, thrusters)

» Power, Telemetry and Command units

» Spacecraft maneuver operations

• ACE software-based system supportfunctions

– Thermal control

– Power, Battery charge management

– Fault protection

– Payload

– 1553 data bus

• Ground System command and telemetryprocessing, data base



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BSS’ Simulation Heritage (1962 - Today)



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BSS’ Standard Software Integrated Development& Validation Process (‘IDVP’)

Flightsoftware

developmentDevelopmentProcess

Missiondevelopmentand support

Onboardcomputer

electronicsdevelopment

Spacecraftconfiguration

Sensor /Mechanism

Development

Validation Activities GroundSegment

Development

Test Activities



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IDVP Timeline & Activity Flow Fully Integratedinto Overall Spacecraft Development



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Control and Dynamics Simulation Lab Developed toSupport Validation Process

‘Brings Together All Elements of ACS Design’



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Role of Simulation Lab in IDVP

Control and Dynamics Simulation Lab (CDSL) represents the focal pointfor attitude control system and flight software development at HSC



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Command & Control Organizational Interfaces& Interactions to Support Validation Process

Attitude Control Subsystem FlightSoftware

SystemEngineering

ACSdesign and

analysis

Subsystemtesting

(I CST,FAMST)

Subsystem engineering

(inc fault protection)Bus

Electronics(SCP, CTCU

Sensors)SpacecraftIntegration

And testSpacecraftsimulation

development

ACSdesign

validation

Simulationlab

Telemetry&

CommandSpacecraftemulator

development

Flight softwaredevelopment

& qual testing

Missionsupport

MissionOperations

StructuresAnd

Mechanisms

SpacecraftPayload

PowerSubsystem

PropulsionSubsystem

ThermalSubsystem



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IDVP Flight Software Development Structure

CustomerInputs

SystemSpecification

Flight OperationsIPT

System/SubsystemEngineering/

Design/Analysis Team

Flight Software V&VTeam

• SW TRR• SWAT (FQT)• SW AR• CSCI Development Test• System Performance• Operations Procedures

System/SubsystemEngineering

RequirementsAllocation Team

CSUCSCITest

Cases

FlightSoftware

BuildsADD, SRS, SRD, IRD and STP

• SW PDR• SW CDR• CSU Testing• CSCI I&T• HW/SW I&T• VDD

Flight Software Development Team

Flight Software Product Assurance Team

Evaluates: • Requirement Compliance • Coding Standards • Design Complexity • Software Reliability

• Independent Flight Software Development and Validation Teams• Flight SW Development Testing & Qualification in Closed-Loop,

Real-Time High Fidelity Simulation using Brassboard SCP



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Independent Teams and Team Responsibilities for ACSDevelopment and Flight Software IV&V

Algorithm Design SoftwareEngineers

Software CSU Implementation

Software CSU Unit TestingSoftware Build Development (CSU Integration) Validation Test

Engineers

MST Test Planning

Mission TeamMST Test Case Development

ACSAnalysts MST: DVMST, FQT, EXMST,

ICST, FAMST

ROPS, PROCS, Console ManualsGSMST, Rehearsals



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Integrated Systems Analysis and Simulation arePrincipal Support to Validation Process

Systemsanalysis andsimulation

Mission/systemrqmts

Test system

Validate

Systemsegment rqmts

Test systemsegments

Subsystemrqmts

Testsubsystems

Unit rqmts Test units

Design and build units



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BSS’ Simulation-based Integrated Process Designed toCoordinate Critical Design and Validation Activities

DevelopmentMST

&ICST

HITL & MST ‘Jr.’



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Key Element of the Validation Process:Common, Validated Simulation Software used in all Phases

Design & Analysis Test Mission Support

High fidelity spacecraftdynamics simulation(ADSIM-SD/fast based)

Non-linear, multi-bodydynamicsHigh fidelity sensor/actuatormodelsIntegrated NASTRANflexible model dataFull environmentaldisturbancesIntegrated Instrument Servosimulations

Control Systems Simulation

State estimators Controller Mode logic

Systemdesign andperformanceevaluation

GroundsegmentelementsFlight

softwareEngineeringmodel controlelectronics

Subsystemtest equipment& Gnd T&C SW

Groundsegment

MST

Mixedsimulationtesting

Input/output

interfacecode

Power/thermalpropulsion/T&C

simulationsIntegratedcontrolsubsystemtesting

SensorsActuators

3-axis motionsimulatorInstruments

Stellar InertialTestbed



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Validation Process SimulationApplications

• Pure Simulation:» ALL simulation code (dynamics and

flight software) programmed usingADSIM and external C routines

» Primary uses:– validate flight algorithms– validate subsystem performance– generate predicts for MST and

mission tests

• Mixed Simulation Test (MST)» Reuse ADSIM/C simulation

dynamics» Actual ADA flight code replaces

simulated ADSIM flight code» Primary uses:

– validate flight software– validate subsystem performance

SimulatedDynamics

(ADSIM, C)

SimulatedFlight Software

(ADSIM)

SimulatedDynamics

(ADSIM, C)

COSIMInterface

Code

Actual FlightSoftware

(ADA)



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ACS ‘Pure Simulation’ Architecture -High Fidelity Spacecraft Dynamics/ACS Simulation Developed & Validated During

Initial Design Phase

SimulatedADD ACSControl

Algorithms

ω θ321

θ



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MST Hosts Exact ACS ‘Pure Simulation’ High Fidelity SpacecraftDynamics/ACS Simulation Developed During Initial Program

Phase

SimulatedACS

ControlAlgorithms

ω θ321

θ



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Spacecraft Dynamics Simulation -Highest Fidelity Achievable to Support ACS Design Verification

TransferOrbit Model

OperationalOrbit Model



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BSS’ High Fidelity Simulations Designed to Pick UpMany Design Errors Not Discovered in Linear Analyses

• Cross Axis Coupling Effects» Dynamics - linear and non-linear effects, time

dependant effects» Flexible dynamics & slosh

• Unit Non-Linearities and 2nd order effects» Sensors (thresholds, deadbands, pre-processing

algorithms, field-of-view limits)» Actuators (quantization, saturation, on/off

thrusters, friction, backlash)• Performance Issues

» Steady State performance» Mode or event transitions

• Non-Linear Control Algorithms» Limits/Thresholds» Phase Plane Control» Modulators (frequency conversion)

• System Level Interactions» Thermal Control» Battery Charge Control» Fault Responses

• Loads & Clearances during DiscreteEvents

» Separation, deployments



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MST Simulation Provides Capability for High FidelityNon-Linear Dynamics Models

(e.g. to simulate complex deployment sequences)

SatelliteStowed for

Launch Satellite Fully Deployed On-Orbit

On-Orbit Satellite



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Simulation Architecture

SD/FAST ROUTINES ADSIM SIMULATION CODE

NASTRAN-basedFlex Model

Add flexible motioneffects to state

derivatives

Calculate StateDerivatives

Integrate StateDerivatives

CalculateComposite Body

Properties Ephemeris &Kinematics

Convert state vectorsto angles, positions,

and rates; rotatevectors betweenreference frames;

propagate quaternion

EnvironmentalTorque Models

Generate disturbanceforces & torques

Apply Forces &Torques to Rigid

Body Model

ESCP or ADSIM CODE

ACS Algorithms(Flight Software)

Determine attitude andcommand actuators

Actuator ModelsGenerate

forces & torques

Sensor ModelsGenerate sensor

output signals



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Common Simulation Process

Develop GeneralSimulation

(ADSIM)

ValidateNon-normal Modes

(not real time)

Generate MSTTest Predictions(not real time)

Develop Real TimeSimulation

PerformMST Tests

Develop NormalMode Simulation

Validate NormalMode

Develop BSE RealTime Simulation

Cross CheckGeneral andNormal Mode

Simulation Results

ADSIM General Simulation

MST Real Time Simulation

BSE Real Time Simulation

Normal Mode Simulation

Simulation Cross Check



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Simulation Development and Validation

• Software module development and test» Develop simulation module by module

» Test each module and document in SDF

• Software module integration and test» Incorporate each module into the larger simulation

» Test integrated system and document in SDF

• Simulation Software Development Folder(SDF)

» Create (or update an existing) SDF for each simulationmodule

– module test

– module integration

» Hold internal design reviews



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Mixed Simulation Testing:Mixes hardware, software and simulation to create a high fidelity,

simulated on-orbit test environment

High fidelity spacecraftdynamics simulation(ADSIM-SD/fast based)

Spacecraftcommand,

telemetry andcontrol units

SCPSensor

datageneration

Sensor Signals

ESCPSimulationcontrol and

operatorinterface

Simulationcontrol and

monitor

ECTCUNon-linear, multi-bodydynamics

High fidelity sensor/actuatormodels

Integrated NASTRAN flexiblemodel data

Full environmentaldisturbances

Actuatordata

transfer

Test System

Real-Time Hardware-in-the-Loop Simulation - Primary Tool to Support Validation Process



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Goals and Objectives of Mixed SimulationTesting Program

• MST brings together in an integrated testenvironment all key elements of ACSdesign

» Flight Computer hardware and software» Sensors/actuators» High fidelity ACS design validation simulation» Flight telemetry and command system» Spacecraft operations ground segment

• In a precisely controlled, high fidelity real-time simulation environment designed to

» Operate ‘as-built’ system in a mission-like setting» Verify design requirements implementation» Verify ACS system design & performance

– Conduct engineering development testing ofcontrol electronics with integrated flightsoftware

– Conduct formal flight software qualification» Conduct ‘burn-in’ thermal cycle testing of flight

control electronics in ‘on-orbit’ environment» Determine ACS design robustness, sensitivity» Support development/validation of spacecraft

mission operations



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Approach to Creating MST System

• Integrate control electronics breadboardand/or flight hardware and with flightsoftware

• Incorporate simulation ‘engine’ capableof executing ‘exact’ simulation codedeveloped/validated during subsystemdevelopment phase

Replaces analytical controller modelswith actual hardware and software

• Provide special signal conditioninginterfaces to link spacecraft electronicsand high fidelity simulation

– Provide sensor data into OBC electronics withidentical input characteristics as actual units(through flight connectors, creating exact signalwaveshape, type, frequency…)

– Receive actuator command data from electronicsfor transfer to and processing by simulation

– Test console to communicate with controlelectronics through standard command and datahandling interfaces

Make the control unit "think" it’s on-orbit



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Two Simulation Test Systems Developed toSupport All MST Activities

MST ‘Jr.’ & Boeing Spacecraft Emulator MST Hardware-in-the-Loop Tester (HITL)

• ACS Design Validation• Flight Software Build Integration &

Development Testing• Mission Procedure Development &

Validation• Operator Training• Mission Rehearsals• RAM Patch Development & Validation• Anomaly Investigation

• Hardware/Software Interface Validation

• Sensor/Actuator/Instrument Interface V&V

• Flight Software Qualification

• Final Phase of SCP Acceptance Test/Burn-in prior to Spacecraft Delivery

• MST ‘Jr.’ & BSE Validation Support



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Test Systems Designed to Support all IDVPActivities and Phases

Process Phases and Flow

Development Mixed SimulationTesting (DVMST)

Integrated Control SystemTesting (ICST)

Long Term Mission &Anomaly Support

Flight S/WMaintenance

Flight S/WQualificationTesting (FQT)

Process Test Environments

MST ‘Jr.’ & MST HITL MST HITL MST ‘Jr.’ Boeing S/C Emulator (BSE)

Mixed Simulation Test Systems

MST ‘Jr.’ / BSE MST Hardware-in-the-loop Tester (HITL)



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Mixed Simulation Test System #1 -Hardware-in-the-Loop Tester (‘HITL’)

MST HITL key features

• Primary COTS hardware andsoftware elements (AppliedDynamics International - ADI)

• Connects to flight orbrassboard SCP, run in real-time with complete sensor,actuator, telemetry andcommand interfaces

• Provide SCP interface to ACSsensors/actuators(replace/mix simulated withbrassboard or flightcomponent)

• Actual CTCU electronics (inc.actual 1553 data bus, groundstation interface)

• Real-time, high fidelityspacecraft dynamicssimulation (reuse of existingdevelopment phase validated‘pure’ simulation)



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HITL also used for Integrated ControlSubsystem Testing (ICST)

• ICST extends MSTenvironment to supportintegration testing of ACSsensors, actuators &spacecraft payloads:

» Replace simulation sensor,actuator, and payload modelswith actual engineeringmodel/flight units

» Integrate 3-axis motiontable(with mounted sensors)with high fidelity simulationdynamics

» Verify individual sensor,actuator, and instrumenthardware and hardware-software interfaces withcontrol electronics (staticallyand dynamically)

» Verify sensor/actuatorsimulation models in MST



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MST Jr, Boeing Spacecraft EmulatorConfiguration - 1

Spacecraft Emulator keyfeatures

• Primary COTS hardware and softwareelements (Applied DynamicsInternational - ADI)

• Actual On-board Computer running inreal-time with unmodified flight code(includes memory, timing, I/O circuits ....)

• Fully redundant On-board Computers

• Actual TT/C electronics (includes actual1553 data bus, ground station interface)

• Real-time, high fidelity spacecraftdynamics simulation (reuse of existingdevelopment phase validated ‘pure’simulation)

• Real-time simulation of all non-ACSsubsystems (power, thermal, propulsion,payload)

• Provides direct link to Satellite ControlCenter or hosts Satellite Control SystemTT/C software

Emulated Electronics• ESCP• ECTCU

Host UNIX workstation (or only X-terminal)• Command/Telemetry I/F — ISI EPOCH 2000• GUI simulation control — ADI Interact• Real-time plotting — ADI SIMplot• ESCP control — Boeing EDB



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MST Jr./BSE Configuration - 2

ADI Real-Time Station (RTS)



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‘E-Product’ Hardware Element - 1Incorporate core flight hardware and software from ACS subsystem

Emulated Spacecraft ControlProcessor - ESCP• Integrates exact SCP on-board

computer» Executes real-time,

unmodified flight s/w

• Processor circuitry takendirectly from flight SCP design

• Uses non-flight versions ofsensor, actuator,communications, fault andsupport ASICs

• Uses FIFOs and dual portmemory for I/O data transfer

• Incorporates SCP 1553 databus remote terminal, linked tobus controller in TT/C emulator

Emulated SCP Flight SCP

ESCP Integration into Spacecraft Emulator



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‘E-Product’ Hardware Element - 2Incorporate core flight hardware elements from TT/C subsystem

Emulated Central Telemetry &Command Unit - ECTCU• Uses non-flight versions

of the uplink and T&CASICs

• Process exact spacecraftcommands

• Uses dual port memoryfor telemetry formatinformation

• Produces completestandard telemetry frame

• Flight bus controller forincorporating actualMIL-STD-1553 data bus

Emulated CTCU Flight CTCU

ECTCU Integration into Spacecraft Emulator



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MST Jr./Boeing Spacecraft EmulatorSystem Architecture



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Commercial-of-the-Shelf (COTS) Softwareused for Spacecraft Emulator Implementation

Applied Dynamics International (ADI) SIMsystem Products



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IDVP Mixed Simulation TestPhases - 1 (and Acronym Explanation)

• Development MST (DVMST)

» Engineering level testing» Incremental testing of integrated flight software builds;

- Tests designed to verify ADD functionality» Test plan created per build by analysts and test

engineers;– Test results derived from ‘pure simulation’ or

analysis activities– Analysts review and sign test cases

» Verifies all ACS System level performancerequirements, ACS design and performance validation

– Customer review and monitor test cases» Problem reports (SW, tester, operator error) tracked

internally, closed by REA signature

• Integrated Control Subsystem Testing (ICST)

» Replaces simulated sensor, actuator and Payloadmodels with actual engineering model and/or flightunits

» Provides for early verification of individual sensor,actuator, and Payload hardware and hardware/softwareinterfaces - both statically and dynamically

» Supports validation of pure simulation sensor/actuatormodels used in MST and GSMST



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IDVP Mixed Simulation TestPhases - 2

• Flight Software Qualification Testing (FQT)

» Independent ACS subsystem engineering team performsformal software qualification testing of SCP CSCI usingMST(to MIL STD 498/2167a ... standards)

» Command files, data under configuration management,SQA involved in test plan/data

» Conducted using brassboard SCP with HITL platform» Test cases defined from actual spacecraft operations

• Flight Acceptance MST (FAMST)» Support Flight SCP Final Acceptance Testing

– Conduct 50 hrs of required SCP burn-in/thermalcycling using real-time, closed loop MST simulationenvironment

» Perform subset of FQT test procedures on flight SCP– Test flight SCP using unmodified flight code, linking

the detailed spacecraft simulation directly to the SCPthru flight connectors

– Execute• Entire mission and on-station sequence• All operational modes, mission phases, fault

response



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IDVP Mixed Simulation TestPhases - 3

• Extended MST (EXMST)

» Post FQT test focused on system performance andoff-nominal performance

» Evaluate system robustness, defined by analysts(perform ACS/Flight SW stress testing)

» Validate dynamic models and linear analysis

• Ground Segment MST (GSMST)» Expands the MST environment to encompass

complete spacecraft and ground segment.» Augments MST high-fidelity ACS simulation with

digital simulation of non-ACS subsystems (power,thermal, propulsion, payloads and telemetry andcommand)

» Supports mission development, preparation, andSatellite Control Center command and controlsoftware validation.

» Develop and validate all spacecraft operational andtest procedures, verify the mission sequence ofevents, provide factory tool for on-orbit spacecraftsupport

» Pre-testing of modified procedures, anomalyinvestigations; development, checkout, andvalidation of flight software modifications



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Validation Process includes GSMST Phase toSupport all Critical Mission Development Activities

Mission planning/preparation• Development/validation of operational procedures• Development/checkout of on-orbit test procedures• Verification of mission sequence of events

Ground station software• Ground station software development• Validation of telemetry and command

databases/processing• Develop/validate ground station attitude

determination/maneuver software• Design/test command procedure software

Training• High fidelity, real time environment for mission

rehearsals• Mission rehearsals from customer/remote ground

station• Customer operator training

End-to-End Testing• Exercise all operational procedures and execute all

spacecraft commands in on-orbit, closed loopenvironment

On-orbit support• Tool for ‘pre-testing’ procedure modifications• Anomaly investigations• ‘RAM patch’ development/checkout/validation• Provide ‘mission oriented’ environment for additional

flight software testing (system ‘stress’ testing)



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Boeing Spacecraft Emulator (‘BSE’)

• The Boeing Spacecraft Emulator(‘BSE’) represents a standardBoeing product integrating

» Extensive COTS hardware and software with» Special Boeing-developed electronic

components, called the ‘E-products’ -emulated spacecraft electronics

• The Boeing goal is to create anenvironment that integrates thesatellite ground system with a highfidelity satellite simulation

» Used to support our satellite and missiondevelopment activities,

» Provide proper development and validationof the spacecraft mission to ensure 100%first mission success, and

» Provide high quality spacecraft simulatorproduct for delivery to our Customers

BSS Test System Integrates GroundSystem with High Fidelity Spacecraft

Simulator



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• GSMST System integrates all critical space/groundsystem elements for support of mission developmentand validation

» ACS hardware-in-the-loop Mixed Simulation Test (with flightcomputers, T&C hardware, and high fidelity closed-loop spacecraftsimulations) used to design, develop and qualify the controlsubsystem

» Simulations of all non-ACS subsystems and instruments

» Customer ground station real-time command/telemetrysoftware/hardware and spacecraft data base

» Customer ground station command generation software

» Customer ground station telemetry processing software

• Provides remote communications capability for linkingSpacecraft Emulator to GOC/SOCC or BSS’ El Segundofacility for Mission Rehearsals



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Concluding Remarks

• The Boeing standard simulation-based verification and validationprocess represents 40 yearevolution of spacecraft simulationtechnology

• Adopted as product validationplatform for all programs

• Provides capability for Boeing to‘Fly the Spacecraft on the Ground’

• Has resulted in 100% successful1st mission on all new Boeingspacecraft


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Simulation through - ADI | Solutions in Real Time