rapid deployment of aerospace flight controls edward l

Edward L. Burnett – MathWorks ADC Lockheed Martin Aeronautics Company – Palmdale (PIRA#AER200605002 )

Rapid Deployment of Aerospace Flight ControlsRapid Deployment of Aerospace Flight Controls

Edward L. BurnettEdward L. Burnett

Lockheed Martin Aeronautics Company Lockheed Martin Aeronautics Company -- PalmdalePalmdaleLockheed Martin Senior Fellow Lockheed Martin Senior Fellow

Modeling, Simulation and ControlsModeling, Simulation and Controls

Presented to:Presented to:The The MathWorksMathWorks Aerospace and Defense ConferenceAerospace and Defense Conference

14 June, 200614 June, 2006



• The Historic Problem

•A Possible Solution

•A Case Study

•Summary


The Problem

•Augustine’s Laws− (Law XVI)

• “In the year 2054, the entire defense budget will purchase just one aircraft”

−Software’s Part (Law XVII)• “Like Entropy”

− “Weight nothing”− “Obeys the 2nd Law of

Thermodynamics; i.e., its always increasing”

MASTERCAUTION

Press to Reset


The Problem

Major Acquisition Process

ATF1983

YF-221st Flt 1991

F-22A1st Flt 1996IOC 2005

AMRAAM 1977 - 1991

A-121983-1991

JSFX-35 1st Flt 2001 F-35 IOC 2008

18 Years

AFX 1991-1994

JAST 1994-1996

Airframe Service Life

1st Flt

1st Flt

1st Flt U-2A

B-52H

U-2S

C-130J

B-52A

XC-130

2001

JSF Selection

1950

A-12 IOC

1960 1970 1980

1982 2001 2008

F-35

1990


The Problem

• However, We Live in a Rapidly Changing World

20001950 1960 1970 1980 1990 2010

9/11/01

Post WWII

Cold War

War on Terror

11/9/8910/4/57


The Problem

•Cost Growth of Flight Controls

DevelopmentCost

$

Software

Electronic Hardware

Actuators

Year

BoosterActuators

StabilityAugmentation

Systems

CommandAugmentation

Systems

IrreversibleActuators

IntegratedServo

Actuators

AnalogFly-By-Wire

Systems

Fly-By-WireActuators

DigitalFly-By-Wire

Systems

AutomaticCode

Generation

Incorporation ofDDV Technologies

FuturePossibleTrends

1940 1950 1960 1970 1980 1990 2000


The Problem

• Integration Issues− Interface Control Documents (ICDs)

• Variable Name• Data Type• Units• LSB, MSB• Update Rates• …


• Looking For Trends in History

Distribution of Severity 1&2 Problem Products(Based on Origination Product Data)

ETS HW/SW15%

OFP27%OS

9%

SDD (Mech)9%

SRS1%

VMC HW8%

VMC IOC18%

VMC DSP5%

VMC CPU1%

Air Data1%

Control Laws4%

VMC ICD (Dual Port or

Hardware)2%(EXEC & PHM)

The Problem


• Software Only − Exec, IOC, DSP

• Classical− CLAWS, Air Data

• MBD

Size of Software ExecIOCDSPAirdataCLAWs

Where the Error Are ExecIOCDSPAirdataCLAWs

Factor of 7 Times More Errors From Classical Process

The Problem


The Problem

• Cost of Software and ICD Fixes

SRR PDR CDR TRR FFRR FF IOC

$ Per Fix

(Log Scale)

Flight Test

IFAT

Integration TestUnit TestFunctional Test

FMET

Specification

$100

The Program


The Problem

• New Challenges –− FAA

• Reliability− Space and Time Partitioning

• UAVs in the NAS− See and Avoid


A Possible Solution


A Possible Solution

•Model Based Design +− Design− Analyze − Deploy − Integrate− Test − Document


• Classical VMS System Development Process

Req.

Errors

SW Implementation

Errors

Errors

DesignCLAWS

Simulate

CODE &Install

Integration& Test

Errors

DELAY

DELAY

DELAY

DELAY

DELAY

DELAY

ErrorsDiag. Implementation

Requirement

Requirement

Diag. Implementation

A Possible Solution


Req.

Errors

Errors

Design & ACG CLAWS Integration

& Test

Errors

Simulate

Errors

All Implementation

DELAY

DELAY

DELAY

DELAY

Requirement

Requirement

Diag. Implementation

Compressed Schedule

Fewer Delays

Compressed Schedule

TIME

A Possible Solution

• Model Based Design VMS System Development Process

ACG = Automatic Code Generation


A Possible Solution

• Model Drawing Standards− The Enabler

• Learning Curve • Model Reuse • Scripts• Tools• Automated Test


FCS_fwrp.f

FCS_wrp_.c

FCS.c

Automatic Code Generation:Template Files, ScriptsCreate C-code and wrappers

/* Real-time model */RT_MODEL_s002fcs s002fcs_M_;RT_MODEL_s002fcs *s002fcs_M = &s002fcs_M_;

void sf_m0_c25_s002fcs(void)

{int32_T i;int32_T ok;int32_T j;real_T temp;i = 0;ok = 0;j = 0;temp = 0.0;j = 0;s002fcs_B.ilimit_c = 1;s002fcs_B.scale_c = 1.0;while(j < s002fcs_B.neff) {

A Possible Solution


A Possible Solution

• Use of Buses and Property Tags− Model Based ICD− Script Testing of Interfaces


A Possible Solution

• Control of Input and Outputs of Sub-Systems− Allows for Automated Test Vector Creation

• Simulation (PIL)• HIL

Iron Bird Testing


A Case Study

• Lockheed Martin – A Recent Example

− Independently Funded Concept Demonstrator

− Rapid Design-Build-Fly Program

− Very Small Team


A Case Study

• Rapid Simulation and Flight Software Development

− Developmental / Analysis Simulation – <1 Month

− Real-Time Piloted Simulation – <2 Months

− HIL & Engineering Test Stand – 7 Months

− SCOs – 9 Months

− Taxi – 12 Months

− 1st Flight – 13 Months


A Case Study

• Only 2 Flight Controls Software Changes− Calibration Tables (Scheduled Update)

• During SCOs

− Flight Test Data Output Update • Ethernet to RS422


• Model Based Design +− Reduces Design Process Delays− Model Drawing Standards

• Reduces Learning Curve• Increases Model Reuse

− Automatic Code Generation• Reduces Manpower Required• Reduces Errors Early

− Embedded ICD in Model• Reduces Errors in Documentation• Reduces Errors in Integration

− Built in Test and Data Pump • Increases Test Efficiency

Reduces Total Time and Cost to Deploy

Summary


Questions?


Never Forget Who You are Working For !