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Cosateq plays key role in development of SSJ100 electronic bird

Few industries are as sensitive to the concept of time-to-market as the aerospace industry, where hightech test stands and simulators are routinely used to shorten product development times and get aircraft in the air and flying. In many ways, however, a recent cooperative effort involving Germany's Cosateq GmbH & Co. KG, a specialist in real-time hardware and software simulators for the aerospace sector, and Liebherr-Aerospace Lindenberg GmbH, a respected developer of fly-by-wire control systems, has been anything but routine.

Liebherr-Aerospace turned to Cosateq GmbH to develop a comprehensive HIL/ SIL test program (hardware in the loop, software in the loop) for the fly-by-wire control system for the Sukhoi Superjet 100 (SSJ100). The SSJ100 is the first Russian jetliner expected to meet Western design and safety standards, giving the aircraft a real shot at becoming a commercial success beyond the borders of the former Soviet Union.

Using its ProSys-RT™ realtime simulation software, Cosateq helped Liebherr develop an HIL/SIL test stand capable of testing individual components and component combinations using a realtime calculation cluster. This makes it possible to test the SSJ100's fly-by-wire systems without the need for real actuators or sensors. Instead, the SSJ100 Electronic Bird uses simulation computers that react to simulated input signals and then deliver realtime simulated sensor signals back to the flight control system.

The real time cluster developed by Cosateq for the SSJ100 Electronic Bird is an extraordinary achievement consisting of 14 simulation systems operating simultaneously with a sampling rate of just one millisecond. Depending on the complexity of the underlying computational model and computer performance, individually modeled systems can achieve sampling rates as fast as 10 mic r oseconds. Communication between the cluster's computational nodes takes place using shared memory on a 2.12 Gbaud glass fiber data network with a latency time of less than 50 microseconds. The system developed by Cosateq makes it possible to completely emulate the SSJ100's actuators and sensors and perform simulated testing of the aircraft's automated components as well as integration and system tests for all control components. Various problem scenarios, including broken wires, sensor failure, communication failures or mechanical problems, can also be simulated. For example, the Electronic Bird can simulate and test the reaction of the control system to a failed actuator drive for one of the SSJ100's control surfaces, a process that includes validation of the system's correct response, its prioritization of information and the communication between components.

Cosateq developed the SSJ100 test stand using ProSys-RT™, a real-time simulation software suite that in many ways represents a quantum leap over conventional tool collections that require time-consuming and expensive manual programming. Prototyping systems like ProSys-RT™ make it possible to test system functionality without programming and independently of the hardware platform. With Cosateq's ProSys-RT™ , for example, aerospace-s p ecific bus systems like ARINC 429, AFDX, CAN and Profinet can be easily integrated in the system's real-time cluster. ProSys- RT™ also supplies interfaces that make it possible to cross-compile and distribute simulation models for different target platforms and to control runtime parameters with a flexible GUI that also makes it possible to analyze and visualize measurement results. According to Cosateq's CEO, Mr. Peter Schilm, the main advantage of ProSys-RT™ lies in its flexibility with respect to hardware environments and in the system's ability to expand and adapt to the integration of additional models and interfaces. Compared to other systems, ProSys-RT™ makes it possible to perform more detailed testing in a shorter period of time, saving money and dramatically reducing time to market. And despite its relatively low cost compared to other systems, ProSys-RT™ can also be used with distributed simulation models and complex real-time clusters without the need for extensive reprogramming. Test programs can be changed in ProSys-RT™ with just a few easy steps.

"The collaboration of Liebherr- Aerospace with Cosateq has resulted in significant progress for both sides," said CEO Peter Schilm. Not only will Liebherr implement all of its future aircraft simulation programs using Pro- Sys-RT™, Cosateq has also implemented improvements to the ProSys-RT™ platform resulting in part from the high demands experienced and the many ongoing changes to the testing programs implemented during the SSJ100 project. Version 4.1 of the software will be distributed on a Debian-Linux Live CD, making it possible to start and install the realtime system directly from the CD without having to previously install an operating system. The new software version also supports Intel's latest Core2Duo architecture and Xenon processors.

The company behind these innovations, Cosateq GmbH & Co. KG, was founded 15 years ago in Wangen im Allgäu and began as an IT service provider for the international simulation software specialist MatrixX. The company quickly grew up to 15 employees – mainly highly qualified engineers from computer science, electrical engineering, and mechanical engineering - to meet the specialized requirements of industrial partners. Continual qualification of the employees and the permanent increase of know-how ensure the professional competence of Cosateq. The company has close contact to the universities of applied sciences in Weingarten and Kempten, as well as the universities in Ulm and Kaiserslautern, enabling it to integrate latest research results into its own product development cycle. Cosateq's customers are mainly well-known companies in the fields of automotive engineering, aerospace, mechanical engineering, press construction, and measurement technology.

Readers interested in learning more about Cosateq can do so at Aerospace Testing, Design & Manufacturing 2008 Munich, Germany. More information is also available from the Cosateq website at www. cosateq.com or by contacting the company directly.

Press release issued by Cosateq GmbH & Co. KG on April 5, 2008


 Contact details from our directory:
Cosateq GmbH & Co. KG Prototyping, Simulation Services, Computer-aided Testing, Computer-aided Analysis, Computer-aided Simulation
Liebherr-Aerospace Lindenberg GmbH Cabin Pressure Control Systems, Electromechanical Actuators, Hydraulic Systems & Equipment, Pressure Control Valves, Mechanical Actuators, Cabin Heaters, Cooling Systems, Aircraft Landing Gear, Helicopter Landing Gear, Auxiliary Power Units, Hydraulic Actuators, Servoactuators, Hydraulic Filters, Wing Spoilers, Wing Flaps, Aircraft Control Surfaces, Fly-by-Wire Systems, Gearboxes, Control Dampers, Gears & Assemblies, Hydraulic Power Supplies, Air Refuelling Systems, Brake System Components, Aircraft Wheels, Tyres, Steering Systems, Hydraulic Pumps, Automatic Flight Control Systems, Hydraulic System Valves


 Related aircraft programs:
Sukhoi SuperJet 100


 Related directory sectors:
Test Services
Design Software
Computer-Aided Testing
Airframe Assemblies

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