Learn about systems integration at OPAL-RT through turnkey RCP/HIL simulator solutions.

1. Aerospace Project Integration
Alexandre Leboeuf, Integration Team Leader at OPAL-RT
October 10, 2013

2. • 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
2

3. A Little About Myself
3
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

4. 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
4
1. http://en.wikipedia.org/wiki/Systems_integration - Consulted on 10/08/2013

5. • 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
5

6. 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
6

7. Systems Integration – OPAL-RT’s Response: Turnkey Solutions
7
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?

8. Components
8
Typical RCP Configuration:
• Host Computer (Host)
• Target Computer (Target)
• Models
• Human Machine Interface (HMI)

9. 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
9

10. Components
10
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

11. 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
11

12. Components
12

13. Components
13
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

14. Components
14
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

15. Components
15
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

16. Components
16
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

17. Components
17
Control Unit (UUT)
Purpose:
To be defined.
Characteristics:
• Your own design
[INSERT YOUR
DESIGN
HERE]

18. Components
18
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

19. Components
19
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

20. Components
20
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

21. 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
21

22. • RFQ
• Quote
• PO
• Design Process
– KOM
– PDR
– CDR
– Production
– Factory Acceptance Tests
– UUT Integration
– Delivery
• Commissioning / Training
• Support
A Project Management Process – Steps Overview
22

23. 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
23

24. 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
24

25. A Project Management Process – Quote and PO
25
Quote Example:

26. A Project Management Process – Quote and PO
26
Along with the quote, you get: (Hardware Overview, Cabinet Configuration)

27. A Project Management Process – Quote and PO
27
Along with the quote, you get: (Hardware Overview, Target Configuration)

28. A Project Management Process – Quote and PO
28
Along with the quote, you get: (Signal and Connection Overview)

29. A Project Management Process – Design Overview
29

30. A Project Management Process – Preliminary Design Phase
30

31. A Project Management Process – Critical Design Phase
31

32. A Project Management Process – Production Phase
32

33. A Project Management Process – Completion Phase
33

34. A Project Management Process – Delivery Phase
34
• 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

35. • 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
35

36. 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
36

37. Success Stories
37
Liebherr Canada

38. Success Stories
38
Liebherr Canada

39. Success Stories
39
Some other systems built:

40. Conclusion
40
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

41. Final Words
41
Questions ?
CONTACT US: 514-935-2323 – info@opal-rt.com