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Real-time HIL test of engine control units for rotary- and fixed-wing aircraft

The FADEC/EEC Test Platform provides a hardware in-the-loop (HIL) closed-loop test environment for dynamic and maintenance testing of full-authority digital engine control (FADEC) and electronic engine control (EEC) units of both rotary- and fixed-wing airframes. The system simulates one or more turbofan engines, including its sensors and actuators for use with the most sophisticated FADECs and EECs on the market. The system delivers repeatable, cost-effective testing in a fraction of the time needed with typical in-house simulation test systems.

The extensive set of I/O channels in the FADEC/EEC Test Platform meet the requirements for a typical mid-sized dual-channel gas-turbine engine control and can be reduced or expanded to the exact I/O requirements for other types and sizes of engines. Customer-proprietary simulation models of the gas path are easily incorporated into the test system software for comprehensive test coverage. The system may be used standalone or as part of a larger System Integration Laboratory (SIL) or Iron Bird.

The test system is based upon the Bloomy Simulation Reference System, which reduces overall lifecycle costs and creates a common test platform for HIL test systems in a System Integration Laboratory (SIL). The reference system includes industry-standard components from National Instruments, The MathWorks, Virginia Panel Corporation, and Bloomy. These components are used in other Bloomy Test Platforms including the Environmental Control System Test Platform and the Flight Control System Test Platform.

Bloomy's FADEC/EEC Test Platform can be used in a range of test system applications including:

  • FADEC/EEC verification, validation
  • Development, production, or maintenance testing
  • “Fly the Box” test of customer return material
  • Development of control laws prior to physical engine test
    • Reduces physical test requirements
    • Minimizes dangerous fault conditions in physical test
  • Environmental Stress Screening(ESS)/Highly Accelerated Life Testing (HALT)
  • System Integration Labs (SILs)

Bloomy's FADEC/EEC Test Platform features include:

  • Simulation environment for comprehensive engine control testing
  • Analog I/O including thermistor, RTDs, strain gages
  • Actuator loads including inductive solenoids, torque motors, and indicator loads
  • Discrete switch signals, including open/ground, open/Vcc, open/closed, and customizable high-resistance state
  • Available digital communications including ARINC-429, MIL-STD-1553B, FireWire, AFDX, serial
  • Simulation-controlled variable DC power supplies; optional 1Ø/3Ø AC supplies
  • ThroughPoint™ Interface Panels with integrated breakout box functionality and high-reliability Virginia Panel interface connectors
  • Optional real/sim. switching for testing real actuators with the system
  • VeriStand real-time framework for integrating customer-supplied gas path and other models
  • TestStand test executive and LabVIEW programming environment
  • Self-test for rapid system checkout and troubleshooting
  • Optional data acquisition for incorporation of real-world parameters into testing
  • Standard configuration for out-of-the-box functionality with typical FADECs/EECs
  • Highly-customizable architecture and interfaces to meet user-defined requirements

Signal Conditioning and Communication I/O
Interface TypeChannels
VDT/Resolver simulation (4W, 5W, 6W)*+8
Thermocouple simulation*+8
RTD simulation*+8
Thermistor simulation+0
Strain Gauge simulation+8
Loads (torque motors, solenoid, lamp, etc.)*+16 (8x <5W, 8x >5W)
Discretes (one-wire and two-wire)+32
Differential analog outputs to UUT+8
Potentiometer/variable resistor simulation8
Ethernet Test BusOptional
DC Power2
AC PowerOptional
Fault Insertion
*Open circuit fault included.
Other fault conditions (short to ground, pin to pin short, etc.) optional for all signal types
+Self-test standard, calibration optional
Loopback self-test optional for all other signal types
Computing Resources
Real-Time Simulation HostPXIe-based, RTOS, up to 8-Core Xeon
Instrumentation and System ManagementPXIe-based, Windows, up to 8-Core Xeon
Software Environments
Real-time FrameworkNational Instruments VeriStand
Test ExecutiveNational Instruments TestStand
Data Acquisition and ProgrammingNational Instruments LabVIEW, C/C++
Data Management and AnalysisNational Instruments DIAdem
Software Models23 model types, including LabVIEW, Simulink, MatrixX, C/C++, MapleSim
System Dimensions and Power
System Chassis1- 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
WeightConfiguration dependent
Power RequirementsPower requirements vary with selected Ac and DC power supply options
Emergency Power OffStandard
Uninterruptible Power SourceStandard for all computing resources
1-year warranty on all hardware components, optional extended warranties available
3-year software service plan on all National Instruments software products

Contact Bloomy for other options.