Aircraft engine FADEC controller development and test platform-EEWORLD

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The current mainstream mode of aircraft engine controller is to use a Full Authority Digital Electronic Controller (FADEC). All control law processing, redundancy management, and input and output signal waveform processing on aircraft engines are completed by FADEC. Designing and developing a high-performance aircraft engine FADEC controller is the most urgent need of my country's aviation industry. How to efficiently and safely test the FADEC controller has become a technical difficulty that needs to be solved in the development process:

• Safety of the test process. Actual aircraft engines need to operate in harsh environments with high temperature, high pressure and high load. In the early stages of development, if an immature controller is used for bench tests, it will inevitably bring various safety risks;

• Completeness of the test. Bench and physical tests cannot simulate certain extreme fault conditions;

• Test development time and cost control. Each bench test takes a long time to prepare, and the economic and labor costs of the test are very high. It is necessary to improve the test efficiency and reduce the test cost.

solution

The world's major aircraft engine suppliers, such as GE, Rolls-Royce and Pratt & Whitney, are using semi-physical simulation testing technology to develop and test FADEC controllers. This technology is based on the real-time model of the aircraft engine and uses a real-time simulator as the hardware support platform. The real-time simulation system runs the real-time model to simulate the real aircraft engine controller, replacing the real engine controller.

The system structure of the aircraft engine FADEC control development test platform is shown in the figure below:

The aircraft engine FADEC controller development and test platform consists of multiple systems.

• Host computer and development platform system, used for system modeling and simulation control

• Real-time simulation system: HiGale real-time simulation system, used to run engine models, including simulation of various sensors, actuators, I/O boards, bus boards, etc.

• Signal conditioning system: used to match and isolate input and output signals, that is, to complete signal transfer and conversion, and simplify the cable network design of the entire platform

• Fault injection system: simulate various sensor, actuator, and bus faults

• Wiring connection system: adapt to the diversity and complexity of signals and manage them uniformly

• Power supply simulation system: used for aircraft power supply simulation and fault injection, PMA simulation and fault injection

• Display system: including 2D and 3D engine display, aircraft visual simulation, etc.

• Comprehensive test management system: unified management of test execution of each system, and automatic completion of test result analysis and report generation

The aircraft engine FADEC controller development and test platform is an integrated real-time simulation and test platform composed of a series of software tools and hardware equipment, which provides a complete tool chain for the aircraft engine FADEC controller development and test platform. The platform has the functions of hardware closed-loop simulation test of aircraft engine FADEC control system, sensor signal acquisition on the tester, simulation of key sensor signals required by the control system, control system fault injection, and engine digital modeling environment.

Although this technology cannot completely replace bench tests, it can greatly reduce and shorten the number and time of bench tests, and has the following advantages:

• Avoid safety issues in the testing process caused by software and hardware defects in the early stages of control system development;

• The real-time simulation system can fully simulate various faults and extreme working conditions that are not easy to occur in the actual working process, and test the control system more comprehensively;

• The cost of purchasing and testing a real-time simulation system is much lower than the investment and cost of using a physical bench test, reducing the customer's risk in development costs.

Reference address：Aircraft engine FADEC controller development and test platform

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