Case Study Real-Time Virtual Test Bed HiL-System
A leading manufacturer of commercial aircraft components turned to Xentara for modernizing and standardizing their bespoke test system architecture. Using Xentara's open interfaces, real-time capabilities and integrated simulation functions, the OEM successfully set up a modular platform for testing multiple components. Project delays and development times were reduced by 30% while system infrastructure cost could be cut by 50%. Integration of tools by Razorcat GmbH also enabled test automation, leading to a 30% boost in testing efficiency.
Customer: DOA-Certified OEM for Aerospace Equipment
“Xentara allows us to not only access thousands of data points from distributed systems under test in real-time, but also run perfect digital and visual simulations of entire airplane control surfaces.”
Global Business Unit Head, Aerospace OEM
The customer, a division of a renowned industrial conglomerate, is dedicated to pioneering the design, development, and manufacturing of cutting-edge aerospace systems and components. Their extensive portfolio encompasses a variety of critical solutions, such as landing gear systems, flight control actuation systems, and air management systems. Catering to a global clientele of aircraft manufacturers and operators, OEM prioritizes innovation and reliability to enhance the safety, efficiency, and performance of commercial, military, and business aviation platforms worldwide.
One of the primary challenges in the development and manufacturing of wing components and landing gears for commercial aircraft OEMs is ensuring strict compliance with international aviation regulations, necessitating thorough testing and certification processes. These components undergo a battery of tests, including structural integrity, fatigue, environmental, and performance testing, which can be complex and resource-intensive. Additionally, ensuring compatibility and interoperability with other aircraft systems poses a challenge, particularly when dealing with multiple OEMs and suppliers. Identifying and addressing design flaws early in the development process is crucial to avoid costly redesigns and delays in certification. Access to specialized testing facilities may be limited, necessitating collaboration with external partners or investment in in-house capabilities. Testing and certification processes can be time-consuming and expensive, requiring careful budgeting and project management to minimize delays and cost overruns. Comprehensive documentation and traceability throughout the process are essential for demonstrating compliance and ensuring transparency during audits or inspections. Overcoming these challenges demands collaboration, innovation, and a steadfast commitment to quality and safety throughout the development and testing phases.
In 2023, the OEM invited embedded ocean to collaborate on the development of a modular, generic test platform.
Our solution to address the rigorous testing and certification requirements is the implementation of an integrated test bed utilizing Xentara as the real-time operating layer. This solution offers specific capabilities tailored to meet the demanding needs of testing and certification, including performance, determinism, and traceability. By leveraging Xentara's capabilities, such as real-time data processing and control, the integrated test bed can ensure precise and reliable testing of wing components and landing gears, providing accurate results needed for certification. Additionally, Xentara's robust traceability features enable comprehensive documentation throughout the testing process, facilitating compliance with regulatory standards and enhancing transparency during audits or inspections.
Overall, the integrated test bed based on Xentara serves as a sophisticated solution to overcome the challenges laid out by OEM, ensuring adherence to international aviation regulations while optimizing efficiency and reliability in the certification process, while also facilitating the openness and flexibility to adapt and expand the system for additional test cases.
Software Components Provided
- Xentara Core for Testing
- Functional Mockup Interface Skill
- CCDL test script language Skill
- Websocket Skill (Server & Client)
- Dolphin PCIe Skill for shared memory
- various I/O interface Skills
- Razorcat TOP / TRM integration
Deliverable Work Packages
- CCDL Skill development
- Simulation and Cosimulation via FMI
- Realization of Test System for commercial airliner subsystems (slat/flap control)
- Integration of further tet systems and electrical cabinets
- Consultation on future universal modular test system concepts
Outcomes Compared to Manual Testing Methods / Bespoke Equipment
Improved Flexibility and Scalability of Test Equipment
- Project delays and development time reduced by 30%
- 50% reduction in test system infrastructure cost
Improved Test Automation
- Testing time reduced by 40%
- 90% increase in reproducibility
Documentation and Analysis
- 40% less documentation effort
- Test efficiency increased by 30%
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