Real-time hardware in-the-loop (HIL) test of flight control systems and energy management for eVTOL aircraft
The eVTOL HIL Test System provides an integrated, closed-loop test environment for dynamic testing of flight control systems and battery management systems for electric aircraft. The system simulates both batteries as well as any control surface activities which may occur during forward flight as well as during transitional flight.
The eVTOL HIL Test System delivers repeatable, cost-effective testing in a fraction of the time needed to create bespoke, custom in-house simulation systems.
In a first-of-its kind commercial application, Bloomy’s premier battery simulator, the 12-cell Bloomy BS1200, is used in conjunction with industry-standard components from National Instruments, The MathWorks, Virginia Panel Corporation, Bloomy and others. Control of the simulations of the aircraft, control surfaces, and the batteries is performed using one common test executive to simplify implementation of System Integration Labs (SILs). Scripted tests created using COTS scripting languages ensure that testing is repeatable and efficient.
Bloomy's eVTOL Integrated HIL Test System can be used in a range of test system applications including:
- System Integration Labs (SILs)
- Development of control laws prior to physical test
- Development, production, or maintenance test
- Environmental Stress Screening (ESS)/Highly Accelerated Life Testing (HALT)
Bloomy's eVTOL Integrated HIL Test System features include:
- World-class battery simulation for battery management system test
- Simulation environment for comprehensive flight control system test
- Analog I/O including thermistors, RTDs, strain gages
- Actuator loads including inductive solenoids, torque motors, and indicators
- Discrete switch signals such as open/ ground, open/Vcc, open/closed
- Digital communications including ARINC-429, MIL-STD-1553B, FireWire, AFDX, serial
- Simulation-controlled variable DC power supplies and 1Ø/3Ø AC supplies
- ThroughPoint™ Interface Panels with integrated breakout box functionality
| Signal Conditioning and Communication I/O | |
|---|---|
| Interface Type | |
| VDT/Resolver simulation (4W, 5W, 6W)*+ | RS-422 |
| Thermocouple simulation*+ | ARINC-429 |
| RTD simulation*+ | AFDX/ARINC-664 |
| Thermistor simulation+ | MIL-STD-1553B |
| Strain Gauge simulation+ | IRIG B |
| Loads (torque motors, solenoid, lamp, etc.)*+ | Ethernet Test Bus |
| Discretes (one-wire and two-wire)+ | DC Power |
| Differential analog outputs to UUT+ | AC Power |
| Potentiometer/variable resistor simulation | |
| Fault Insertion | |
|---|---|
| *Open circuit fault included. | |
| Other fault conditions (short to ground, pin to pin short, etc.) optional for all signal types |
| Self-Test | |
|---|---|
| +Self-test standard, calibration optional |
| Cell Channel Simulation | |
|---|---|
| Simulator Type | Bloomy BS1200 |
| Number of Channels | 12 |
| Channel Type | Sink and Source |
| Voltage Range | 0.0 to 5.0V |
| Voltage Resolution | 0.1 mV |
Voltage Accuracy | ±3 mV |
| Current Range | ±500.0 mA (output derates linearly under 2V) |
| Current Resolution | 0.1 mA |
| Current Accuracy | ±4 mA |
| Current Limiting Accuracy | ±10 mA |
| Isolation | 1000V * |
| * Precautions are required for voltages exceeding 140V. Please refer to Application Note 8700- 00038: Using the Battery Simulator 1200 in High-Voltage Applications. | |
| Channel Readback | |
|---|---|
| Voltage Resolution | 0.1 mV |
| Voltage Accuracy | ±3 mV |
| Current Resolution | 0.1 mA |
| Current Accuracy | ±4 mA |
| Digital I/O | |
|---|---|
| Channels | 8 (bidirectional) |
| Logic Level | 3.3V |
| Computing Resources | |
|---|---|
| Real-Time Simulation Host | PXIe-based, RTOS, up to 8-Core Xeon |
| Instrumentation and System Management | PXIe-based, Windows, up to 8-Core Xeon |
| Software Environments | |
|---|---|
| Real-time Framework | NI VeriStand |
| Test Executive | NI TestStand, Python |
| Data Acquisition and Programming | NI LabVIEW, C/C++ |
| Data Management and Analysis | NI DIAdem |
| Software Models | 23 model types, including LabVIEW, Simulink, MatrixX, C/C++, MapleSim |
| System Dimensions and Power | |
|---|---|
| System Chassis | 1- or 2-bay 40U equipment racks |
| 1-bay: | approx. 78"H (with locking casters) x 23"W x 36"D |
| 2-bay: | approx. 78"H (with locking casters) x 46"W x 36"D |
| Weight | Configuration dependent |
| Power Requirements | Power requirements vary with selected Ac and DC power supply options |
| Emergency Power Off | Standard |
| Uninterruptible Power Source | Standard for all computing resources |
| Warranty | |
|---|---|
| 1-year warranty on all hardware components, optional extended warranties available | |
| 3-year software service plan on all NI software products |