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ERS Case Study: HCLT develops a slat flap control unit [sfcu] for an Aerospace client


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ERS Case Study: HCLT develops a slat flap control unit [sfcu] for an Aerospace client

  1. 1. HCL develops a Slat Flap Control Unit [SFCU] for an aerospace client BACKGROUND  Our client is a diversified company whose products include aerospace systems, aircraft engines and helicopters  It wanted to join hands with an engineering partner for its Power Systems division - to quickly ramp up its system capacity and capability to become a strong systems provider.  It chose HCL on account of our vast experience in providing similar services to other aerospace companiesCHALLENGES / OBJECTIVES The card incorporated in the existing SFCU was failure-prone due to poor design SNAPSHOT of the analog and angle measurement circuitry. There were problems also in the  Horizontal: Engineering and R&D Services ASIC [application-specific integrated circuit]. These issues caused frequent false  Micro-vertical: Aerospace alarms and resulted in ‘auto throttle chop’. This required us to perform electronics engineering, software verification & validation, and test and certification support for  Service Areas: Application Engineering & Development, Verification & Validation, the unit Testing, Application Support Redesign & development of the A2 microprocessor board; Design & development  Highlights: SFCU controller card redesign of the tester for the A2 board, and of the Primary Processor Fault Manager and ASIC to FPGA conversion following software to DO-178B level-A compliance; Verification of all software change DO254 level ‘A’ standards; Diagnostics requests for Build–15 of the SFCU; Design & development of the necessary Software & Tester for debug & validation of electronic interfaces for the full wing stand for carrying out SFCU system level the SFCU controller validation testing, and support for various other activities pertaining to SFCU qualification & certification
  2. 2. THE SOLUTIONThis relationship has grown from working on a small mechanical system for a single division, to Our client follows ACE (Achieving Competitiveworking across all major divisions such as the Air Management System, Electrical System, Excellence) as its business operating systemActuation System and Power System, providing services across hardware, software, sub-systems, which HCL adopted in 2005. HCL has sincetest equipment, mechanical engineering, value engineering, and more. progressed from bronze to silver and is currently performing at gold levels while pursuing the newly The purpose of the SFCS is to position the Slat and Flap control surfaces as per established Supplier Gold status. In 2008 our client aircraft system commands, prevent motion of the surfaces that are not commanded, implemented a value creation council which and protect against failures that might cause erroneous positioning of the surfaces, comprised also of HCL members. This transformed erroneous surface position reporting, or unsafe surface operating conditions. The the engagement, as HCL engineers went beyond system also performs Built in Test (BIT) and auto–rigging functions the contract, unlocking savings potential through Our solution involved: new ideas, innovations and productivity  Board re-design for the Slat / Flap Control Unit, addressing reliability issues improvements. Within 15 months the value and replacing components that are obsolete creation council received 200 ideas, which it screened and approved. The dollar savings  Re-designing the Controller ASIC into FPGA [Field-programmable Gate number assigned to each idea based on likely Array] for message transfer between Control and Monitor processors business impact resulted in 13% savings on the  Independent V&V of application software total spend with HCL - a major success achieved  Development of the tester and diagnostic package for hardware testing of the by any supplier and well recognized across our SLAT/FLAP Controller clients leadership team. In recognition, HCL was  System and flight safety tests support awarded the “Highest Value Add Partner” for  Documentation for production 2010.RESULTS / BENEFITS Comprehensive and traceable requirements planning documents enabled a review of records (to support certification) The entire ASIC was redesigned into a new FPGA to avoid failures The right chip was suggested and incorporated to make the working of the SFCU efficient and flawless Highlights: Provided dual processor architecture using 80C186XL & 80C32 processors with dedicated Flash, RAM and Watch Dog circuitry for each processor; ARINC 429 (1Tx+5 Rx) & MIL 1553 controller in custom FPGA (Actel Ax1000) along with DPRAM interface ; Thermal, structural and EMI analysis; LVDT(4), RVDT(4), RDC(2) controller & interface
  3. 3. Hello, I’m from HCL! We work behind the scenes, helping our customers to shift paradigms and start revolutions. We use digital engineering tobuild superhuman capabilities. We make sure that the rate of progress far exceeds the price. And right now, 88,000 of us bright sparks are busydeveloping solutions for 500 customers in 31 countries across the world.How can I help you?