Software Development and Verification for Data Concentrator Unit, Critical Flight Control Computer and Engine Speed Controller

about project

Autoflight X required the development and verification of critical software components for their eVTOL prototype. The project involved development and verification software for the Flight Control Computer (CFCC), Engine Speed Controller (ESC), and Data Concentrator Unit (DCU).

Each component was essential for ensuring the aircraft's ability to control the electromotor, manage data flow from various sensors and control systems. CFCC was particularly crucial as it contained all the flight control laws and was responsible for managing the eVTOL's flight operations.

All development and verification activities adhered to aerospace standards, particularly DO-178C and ARP4754A, ensuring the safety and reliability of software and systems.

Tasks

Development of Plans and Standards:

Establish and document the development plans and standards for each software and system component, ensuring compliance with DO-178C and ARP4754A standards.

Requirement Specification:

Develop detailed software requirements for the CFCC, ESC, and DCU, aligning them with the overall system architecture and safety objectives.

Software Development and Verification:

AFX CFCC: Develop and verify the software for the Critical Flight Control Computer (CFCC), which contains the flight control laws and manages the eVTOL's flight operations

AFX ESC: Develop and verify the Engine Speed Controller (ESC) software, which manages the electromotor’s speed in accordance with flight control computer requests.

AFX DCU: Develop and verify the Data Concentrator Unit (DCU) software, which consolidates signals from multiple sources (such as GPS sensors and radar altimeters) and converts them into CAN and ARINC 429 messages.

Preparation of Certification Documentation:

Prepare the necessary certification documents for each component, in line with DO-178C and ARP4754A standards.

Results

Successful Development and Verification:

Each software component (CFCC, ESC, DCU) was successfully developed, verified, and debugged using test benches, ensuring they met all performance and safety requirements.

Integration into Aircraft:

The prototypes were delivered to the customer, successfully integrated into the aircraft.

Tech Stack and Standards

  • AFX CFCC:
    • Technologies: C, CAN Aerospace, ARINC 429, MATLAB/Simulink, micrium RTOS, PowerPC,
    • Standards: DO-178C, ARP4754A
  • AFX DCU:
    • Technologies: C, ARINC 825, ARINC 429, RS232
    • Standards: DO-178C
  • AFX ESC:
    • Technologies: C, CAN Aerospace, PMSM (Permanent Magnet Synchronous Motor)
    • Standards: DO-178C, ARP4754A

process

Project Implementation

Development of Plans and Standards

The project began with the creation of detailed development plans and standards for each software and system component, ensuring alignment with DO-178C and ARP4754A requirements.

Requirement Specification

Detailed software requirements were developed for the CFCC, ESC, and DCU, outlining the necessary functionality.

Software Development and Verification

- For the CFCC, we developed software to manage eVTOL flight operations and store all flight control laws.

- For the ESC, we created software to manage the electromotor’s speed based on inputs from the flight control computer.

- For the DCU, we developed software to consolidate and convert signals from various sensors and control systems.

Prototype Testing and Integration

Each prototype was tested using a test bench, debugged, and successfully integrated into the eVTOL aircraft.

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