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INDUSTRIAL AUTOMATION AND AVIONICS
Case Study
Industrial Automation and Control Systems
 
CAN based simulator for testing central controller in cabin systems
 
 
The client
The client specializes in the manufacturer of comprehensive cabin system solutions for passenger aircrafts and is a subsidiary of the world’s leading manufacturer of aircrafts.
 
The challenge
Development of central controller had to be DO – 178B process compliant and had to undergo extensive testing to meet reliability requirements.

Testing involved a large set of parameters for numerous on-board devices in all possible combinations, which in a real-life environment is very expensive and time consuming. Unavailability of a complete set of hardware due to concurrent development made recreating actual test set-ups infeasible.

 
Wipro solution
Integration of diverse knowledge areas
Wipro brought together its expertise in diverse areas to create the complete hardware and software design specifications for the product.
Safety critical software development
Embedded microcontroller design with strict safety standards
Simulation & comprehensive testing expertise

“Virtual” airborne system environment
Wipro designed and developed a highly extensible CAN-based device simulator framework recreating the collaborative behavior of on-board devices (see Fig.) The system simulated both messages from central controller over CAN bus and the dynamic responses of pre specified devices.

A feature-rich, customizable GUI allowed many devices to be configured and simulated in multiple CAN-bus configurations. The simulator could save and restore configuration data in XML file format.

Central controller and high power analog input simulator development
The framework developed for device simulation was reused and extended to create a central controller simulator for simulation of high power analog inputs of on-board devices. 90% requirement coverage testing was simulated done offshore.

On-Schedule delivery
Wipro used its strong processes to manage frequent requirement changes. Extensive prototyping was done and client approval was obtained at each stage ensuring on-time delivery of the simulator with complete testing and zero post-delivery defects.

Complete testing of airborne systems
Multiple test cases including abnormal devices and extreme environmental conditions along with destructive testing of a part or whole of the airborne system were simulated. Simulation helped compress the testing time drastically.

 
Benefits
Achievement of critical development milestones
The client could timely achieve critical milestones with cost savings. Use of proven design methodologies and processes helped in crashing the critical development path.

Cost savings
One-time benefits gained from offshore development. 90% requirement coverage testing done offshore saving costs. Availability of simulator translated into huge cost savings for the client by removing the need for costly and time-consuming test set-ups.

 
Technology used
Hitachi H8-2638 processor
Rhapsody in MicroC as design tool
Finite state machine design
Windows based application software using VC++/MFC
 
 
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