The Case for a Generic Systems Integration Laboratory y( (GSIL)

Transcription

1 The Case for a Generic Systems Integration Laboratory y( (GSIL) ITEA 2012 Technology Review Memphis, Tennessee July, 2012 Karl S. Forsstrom Systems Test Engineering Fellow Northrop Grumman Corporation 1

2 Integration and Test of Large Aerospace Systems Examples with Start Dates Large Transport Aircraft Military Weapon Systems Space Shuttle & Missiles Spacecraft & Space Station B-2 Apollo 1965 C B ISS 1993 V STS 1972 A GMD 1998 F F Orion 2006 B

3 Role of Systems Integration Laboratory (SIL) Test Like You Fly Test every aspect of subsystems and of the fully integrated system that is practical to test in a controlled laboratory environment Test with actual flight hardware and software Use simulators and stimulators to provide realistic data inputs and feedback Recognize exceptions to Test Like You Fly philosophy Can t be done because of physics Not practical to do without compromising the engineering results Cost, schedule or other constraints Example of generic Systems Integration Laboratory (SIL) 3 Simulation Cockpit Flight Hardware in SIL SIL with Iron Bird

4 Typical SIL Issues and Implementation Problems Faced by New Programs 4 SIL unavailable to support proposal effort for capturing new program No legacy of designing g or using a SIL Existing SIL from previous program overbooked, technologically obsolete or irrelevant to new program After contract award, SIL design and implementation relegated to tail end of program, i.e., to the Verification and Validation (V&V) phase Failure to recognize importance of involving System Test during System Requirements phase to adjudicate testability of system requirements Late start of SIL design will impact Initial Operating Capability (IOC) date Lack of relevant SIL design and operational skill- and knowledge-base Contracts large enough to need a SIL are relatively infrequent (every 4 6 years) Without new large contracts, SIL design expertise evaporates to other projects or other companies Without new large contracts, SIL hardware and software technology advances never materialize Overall consequence if SIL does get built on time (unlikely), it doesn t perform properly to meet first flight schedule impacting overall program cost and contract success

5 The Case for a Generic Systems Integration Laboratory (GSIL) Questions I will address in next 20 minutes What are the primary elements of a military airborne weapon system? What kind of integration and test research facilities do aerospace companies need to keep up with the competition? How is Northrop Grumman addressing this issue? What are the components of the proposed Generic Systems Integration Laboratory (GSIL)? Does a GSIL make technical, economic and, in the end, good business sense? 5

6 Weapon System Development Center (WSDC) GSIL is central focal point of a broader Weapon System Development Center (WSDC) WSDC works with emerging programs to tailor researchers activities towards desired system requirements WSDC provides structure and organization to inject those new system requirements to individual research areas with IR&D and CRAD projects WSDC assists in acquiring needed laboratory facilities for IR&D and CRAD projects GSIL is a system-level testbed for integrating promising research products from the IR&D and CRAD projects into an existing weapon system framework simulation standard WSDC imposes standards on GSIL framework to ensure technology is consistent with future requirements and state-of-the-art Common System (VMS) Real-time Component Framework (RTCF) Avionics Open Systems Architecture (AOSA) Net-centric Reference Framework (NCRF) 6

7 Common System (VMS) 7 High-speed Serial Bus (IEEE 1394b) GPS/INS 1 GPS/INS GPS/INS Navigation 1 1 GPS/INS 1 Navigation Navigation Navigation FADEC FADEC 1 Engine 1 FADEC FADEC Engine 11 Engine ler Engine ler ler ler Air Air Data 1 Density Data 1 Air Air Density Data Data 11 Density Bar Altitude Density Bar Altitude Bar α, Altitude β Bar α, Altitude β α, β α, β SMS SMS 1 Stores Stores Manage- Managemenment System System Weapon Weapon Bay Bay NWS/Brakes Nose Wheel NWS/Brakes NWS/Brakes Nose Wheel Nose Steering Wheel Nose Steering Wheel Steering Steering Brakes Brakes Brakes Brakes To Mission Systems Network Computer 1 Computer 1 Computer 1 Computer 1 Flight s Redundancy ECS ECS ECS ECS 1 Cross Channel Data Link Environmental Environmental Environmental System Environmental System System System FCAS FCAS Actuator FCAS FCAS Actuator 1 Actuator Remote At Actuator Remote t Remote Terminals Remote Terminals Terminals Terminals Surface Surface Surface Actuators Surface Actuators Actuators Actuators Remote Remote I/O 1 I/O n Inceptors Inceptors Discretes Discretes EPS EPS EPS Electrical EPS 1 Electrical Electrical Power Electrical Power Power Power Load Load Load Balancing Load Balancing Balancing Balancing Common VMS Architecture Tri or Quad Redundancy

8 Real-time Component Framework (RTCF) Components constructed during boot process Components share data via connectors using ActiveX automation Components implement a Run method to process their data 8 Execution of the component is deterministic and periodic Data to and from the component are communicated via connection points, e.g., a Get (Input) or a Put (Output)

9 RTCF Frame-based, Pre-emptive Scheduling Periodic processing with tasks executing in pre-allocated time-slices within major frames Minor frames are multiples of major frame, i.e., 2x, 3x, 4x major frame Unscheduled discrete events execute in frame s available idle time ISR Pi Priority it 1 Priority 2 Priority 3 External Hardware Interrupt Internal Software Interrupt Idle time Simulation Major frame frame 0 10 ms 20 ms 30 ms 40 ms Flight 100 Hz Priority 1 IMU 100 Hz Priority 1 Air 25 Hz Priority 2 Interrupt Service Routine (ISR) Highest Priority Unscheduled Discrete Event Priority 3 Idle Time 9

10 Avionics Open Systems Architecture (AOSA) 10 Service Oriented Architecture Common business practices packaged as services Discovered within the local data structures or external GIG Mediated to select the most appropriate p service Requested to provide or exchange data with a requestor Middleware Software connecting application programs to operating system Isolates applications from operating system- or hardware platform-unique characteristics Simplifies exchange of data Global Information Grid (GIG) Globally interconnected, end-to-end set of information capabilities, associated ated processes, and personnel e For collecting, processing, storing, disseminating, and managing information on demand to war-fighters Avionics Open System Architecture (AOSA) Service Oriented Architecture (SOA) SOA Embedded Embedded Open System Architecture Sensors (radar, EO, EW, etc.) Communications Middleware Core Processor Communications I/O Middleware Avionics SOA Ground Station SOA Global l Network User SOA Communications Beyond-Line-of-Sight/Line-of-Sight Shared Data Storage Datalinks Communications Link Bridge to GIG ISR tasking Global Information Grid (GIG) Exploitation Applications Search Services; Intel Users

11 Net-centric Reference Framework (NCRF) Comm 1 Comm 2 Comm 3 Hardware & Operating System Se Se Se App 1 App 2 App 3 ervice 1 ervice 2 ervice 3 11

12 Modeling and Simulation (M&S) Infrastructure latform Inde ependent mulation Fr ramework P Si Platform Depende ent User Interface (control and display) Test ler (manages component information flow ) Model 1 Model 2 Model 3 Model n Simulation Engine (task scheduling) Middleware (isolates applications from OS/hardware) Operating System (system/file services) Simulation Hardware Platform/Computer 12

13 GSIL Simulation Hardware Commercial-off-the-Shelf (COTS) standard components and data busses Expect technology refresh every 4 5 years To Aircraft Data Busses Data Acquisition System Data Processor I/O Interfaces Mass Storage Data Analysis Operator Console Real-time Simulation Computer x86 Multi-core Multi-core Multi-core Multi-core Mass Mass Storage Storage (SATA) (SATA) Memory Memory Memory Memory Northbridge (Memory ler Hub) Southbridge (I/O ler Hub) PCI Express PCI Express USB To Aircraft Data Busses MIL-STD 1553 MIL-STD 1553 Fibre Channel Fibre Channel Fibre Channel IEEE 1394b IEEE 1394b SCRAMNet Simulation Input/Output Graphics IEEE 1394b Ethernet PCIx PCIx 13 Simulation Network (e.g., Ethernet, SCRAMNet)

14 System (VMS) Integration Test Station (VITS) Computer 1 CCDL Computer 2 Computer 3 Computer 4 VMS System Network (e.g., IEEE 1394b) Integration and test of VMS operational Data Operator Real-time software (CSCI) Acq. Console Simulation Computer CSCI Formal Qualification Test (FQT) Other VMS sub-systems (engine, air data, actuators, etc.) modeled in simulation computer Simulation Input/Output Simulation Network (e.g., Ethernet, SCRAMNet) 14

15 Mission Systems (MS) Integration Test Station (MITS) Mission Systems Avionics System Network (e.g., Fibre Channel, IEEE 1394b, Mil-Std 1553) Core Fabric Core Enterprise Service Bus ADC/DAC & ADC/DAC FPGA & (PMC/XMC) FPGA (PMC/XMC) Avionics Core Specialized Processor Specialized Specialized (Signal/Image Processor (Signal/Image Processor Processor) Processor) (Signal/Image Processor) General System I/O Processor General Core Fabric Purpose System I/O Purpose General Core Switch Fabric Network with Processor PMC/ Network with PMC/ Purpose Switch Switch XMC Switch XMC Avionics System Network (e.g., Fibre Channel, IEEE 1394b, Mil-Std 1553) Integration and test of MS operational software (CSCI) CSCI Formal Qualification Test (FQT) Other MS sub-systems (sensors, communications, etc.) modeled in simulation computer 15 Data Acq. Operator Console Real-time Simulation Computer Simulation Input/Output Simulation Network (e.g., Ethernet, SCRAMNet) Simulation & Data Collection

16 Crew Station or Mission Center COTS LCD monitors with touch screens for virtual cockpit displays COTS LCD monitors for Outthe-Window COTS Side-stick controllers and throttles 16

17 GSIL Integrated System Test Line Mission Systems Avionics Sensors and Communications Subsystems Simulation Network (e.g., Ethernet, SCRAMNet) Radar Active Electronically Scanned Array (AESA) Antenna Navigation Identification Friend or Foe (IFF) Beyond Line. of.. Sight (BLOS) Line of Sight Electro-optical Electronic Warfare Comm (LOS) Comm Sensor Subsystem Signal & Proc. RF Electronics (Receiver & Exciter) EGI w/anti- Jam GPS IFF Transponder UHF/VHF Radios Datalink Subsystems Electro-optical/ Infrared Subsystems Electronic Attack, Protection & Support (EA, EP, ES) Weapons Stores Processor Shared Data Storage Avionics System Network (e.g., Fibre Channel, IEEE 1394b, Mil-Std 1553) Ground Support RIO S1 S1 Sn RIO S1 S1 Sn Core Fabric Core Enterprise Service Bus Image Gene erator - OTW Crew Station s & Displays Display MFD Proc. 1 MFD Display Proc. 2 PVI Switchology ADC/DAC & ADC/DAC FPGA & (PMC/XMC) FPGA (PMC/XMC) Avionics Core Specialized Processor Specialized Processor Specialized (Signal/Image Processor Processor) (Signal/Image Processor) (Signal/Image Processor) General System I/O Processor General Core Fabric Purpose System General Core Fabric Network I/O with Processor PMC/ Purpose Switch Network Purpose Switch Switch with XMC PMC/ Switch XMC Avionics System Network (e.g., Fibre Channel, IEEE 1394b, Mil-Std 1553) Multi-spectral Multi-spectral Stimulator Multi-spectral Stimulator Stimulator Data Acq. Operator Console Real-time Simulation Computer Simulation Input/Output p CCDL Computer Computer Computer Computer 17 Simulation Network (e.g., Ethernet, SCRAMNet) Simulation, Stimulation & Data Collection Engine ler Electrical System VMS System Network (e.g., IEEE 1394b) Landing Gear Actuation System Effectors System Environmental System

18 GSIL Lifeline Usage and Growth Engineering toolbox and testbed Proposal and early contract prototyping Program-unique System Integration Laboratory point of departure GSIL grows and is current with infusion of new technology 18

19 Conclusion Is a GSIL a Good Investment? Engineering toolbox and testbed for a variety of systems related IR&D and CRAD studies Maintains engineering and system test skills between major programs Provides real engineering data and customer demonstrations during proposal stage Point-of-departure for a new project-specific SIL Lowers risk of missing i project-unique SIL s operational date for starting system test Issue of GSIL cost, affordability and sustainability Corporate profits pays for GSIL Get corporate buy-in by showing a good Return on Investment (RoI) Keep GSIL as simple as possible Let contract dollars pay for complex program-unique SIL Get Corporate commitment to sustain WSDC and GSIL for at least five years Give GSIL sufficient time to demonstrate its worth in capturing new business 19

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