Industry 4.0 Technologies as an Obsolescence Mitigator for Testing of Mechatronic Systems in Aviation
Abstract
:1. Introduction
1.1. The Structure of the Work
1.2. Problem Statement in the Context of Obsolescence
- The card can be found to be defective—the chance of the defect of an I/O card within first four years of the operation is at 50% [4]. Inevitably, the operating company will face a situation where the defective I/O card is no longer maintained, and a simple replacement is no longer possible. Since the I/O card consists of software and hardware (driver and PCI or VME card), the change of hardware requires the change of software and the reimplementation of all of the accessing proprietary components.
- Following a necessary upgrade of the operating system of the test bench, the new version no longer supports the I/O card. In this case, the I/O card will need a replacement to a variant that supports the new version of the operating system with all the consequences of the first case.
1.3. Design Methods against Obsolescence
1.3.1. Openness of a System
1.3.2. Modularity
1.3.3. HAL
1.4. Objectives Development—Industry 4.0 as a Problem Solver in Obsolescence
2. Materials and Methods
2.1. Relevant Featurs of Avionics and Test Benches
2.1.1. Reactive Real-Time Systems
2.1.2. Components of an Avionics System
2.1.3. Product-Side I/O Example for the ARINC 429
2.1.4. The Test Bench
2.1.5. Description of the Functional Test at Airbus in the HighLift Use Case
- Signal acquisition begins with the reception of a complete message. The message is interpreted in the I/O card and passed through the PCIe bus to the main processor and the operating system.
- The driver for the PCIe I/O card is integrated within the operating system. The driver provides an interface that is addressed by the application software.
- The application layer transforms the data into a format that the applications can interpret.
- This means that a 32-bit ARINC 429 message becomes information after decoding, according to the configuration (example: temperature of hydraulic oil: 50°).
2.2. The Concept of Open, Syntactically Describable Interfaces for the HiL Test Benches
- in the I/O or standards, the software part (driver) is related to the hardware part (I/O card). This means that the I/O standards that contribute to solving the hardware-to-hardware obsolescence must also contribute to solving the software-to-hardware obsolescence and vice versa. For this reason, the hardware-to-hardware obsolescence is only implicitly considered.
- Care is taken to ensure that the hardware part conforms to a standard that is no less common than PCIe. Technologies, based on fieldbuses are more prone to obsolescence than PCIe and Ethernet. For this reason, Ethernet can be used as a standard.
- The avionics system operates under hard real-time conditions. This means that the test bench and its I/O must also operate under those conditions. This point limits the choice of I/O technologies to only a few candidates.
2.3. Interoperability at the System Level
2.4. Interoperability at the Syntax Level
3. Results
3.1. Implementation of the Open and Standardized I/O
3.1.1. Configuration and Integration of the EtherCAT Master
3.1.2. Implementation of the ARINC 429 EtherCAT Slave
3.2. Syntactic Description of the I/O
3.3. Validation
3.3.1. Application Scenario–Test Bench Interconnection
3.3.2. Application Scenario–Test Slat Electric Motor Failure Injection
3.3.3. Application Scenario–Functional Test of the Airbus A350-1000 HighLift System
- routes the ARINC 429 bus over the standardized I/O and does not compromise the real-time capability of the SuT and the test bench,
- can be configured via the test bench and the standardized medium,
- can translate the test bench variables into ARINC 429 messages,
- can translate the ARINC 429 messages into test bench variables.
3.3.4. Measurement Setup for Measuring the Signal Propagation Delay
3.3.5. Replaceability of the I/O Cards Used
4. Discussion and Outlook
4.1. Challenges and Findings
4.2. Implication for Practice
4.3. Brief Discussion on Standards
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
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Klein, K.; Thoben, K.-D. Industry 4.0 Technologies as an Obsolescence Mitigator for Testing of Mechatronic Systems in Aviation. Appl. Sci. 2022, 12, 11142. https://doi.org/10.3390/app122111142
Klein K, Thoben K-D. Industry 4.0 Technologies as an Obsolescence Mitigator for Testing of Mechatronic Systems in Aviation. Applied Sciences. 2022; 12(21):11142. https://doi.org/10.3390/app122111142
Chicago/Turabian StyleKlein, Konstantin, and Klaus-Dieter Thoben. 2022. "Industry 4.0 Technologies as an Obsolescence Mitigator for Testing of Mechatronic Systems in Aviation" Applied Sciences 12, no. 21: 11142. https://doi.org/10.3390/app122111142
APA StyleKlein, K., & Thoben, K.-D. (2022). Industry 4.0 Technologies as an Obsolescence Mitigator for Testing of Mechatronic Systems in Aviation. Applied Sciences, 12(21), 11142. https://doi.org/10.3390/app122111142