Onboard Systems Design

Degree in
Aerospace Engineering PRACTICE “OSMC Test Bench Practice”

Name:

- OSMC Test Bench Practice -

OBJECTIVES

The objective of the practice on the OSMC Test Bench is to allow the student to have a
contact with an actual aeronautical system integration environment. This contact will
allow the student to understand:

 How aeronautical equipments are usually integrated.

 What are the main parts of an integration bench.
 Which are the steps to define and execute a system test.
 How requirements are verified and validated by means of tests.

The OSMC Test Bench will be used for this task. In a first step, an introduction about
the OSMC Test Bench will be provided to the students, in order to allow them to get
confidence with the testing environment.

In a second step, the students will have a pre-assigned task that must read and prepare
before the session takes place. The task will consist on defining a test case/s based on
the equipment requirements and the bench test environment. Students will prepare the
test procedure before the test session takes place. The test will be defined based on the
template given in ANNEX A. A memory with the proposed test case/s shall be
delivered at the beginning of the session, which will be assessed and will contribute to
the assessment for the continuous evaluation.

In a last step, students will use the session on the OSMC Test Bench to execute and
refine the prepared test. By executing and refining the test procedure, the student will
understand how the system works and how it is verified/validated. The students will
have to make a final presentation in front of the teacher to execute the refined
procedure; this final presentation will be evaluated as an additional assessment of the
practice.

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 Onboard Systems Design
Degree in
Aerospace Engineering PRACTICE “OSMC Test Bench Practice”

Name:

OSMC GENERAL INTRODUCTION

The Open System Mission Computer (OSMC) system is a Basic Avionics System. This
Basic Avionics System is a powerful Communications, Navigation and Identification
(CNI) system plus fuel and engine parameters monitor. The communications sub-
system integrates two VHF/UHF Radios. The navigation sub-system performs
navigation and steering functions. The navigation information is collected from the
sensors: Automatic Direction Finder (ADF), Air Data Computer (ADC), Enhanced GPS
and Inertial Computer (EGI), Flight Control System (FCS), TACtical Air Navigation
System (TACAN), VHF Omnidirectional Range (VOR), Distance Measuring
Equipment (DME) and Instrument Landing System (ILS). A steering module has been
developed in the mission computer (OSMC) and the navigation and steering
information is presented to the Pilot. A digital Map is used as part of the navigation
aiming for the Pilot. The identification sub-system integrates a transponder Modes 1, 2,
3A, C and 4. The fuel and engine parameters are available for display.
In addition to the Basic Avionics System the following Specialized Packages are
included: Weapons Management and Control, A/A and A/G Radar, Tactical Data Link,
Tactical Communications, Target Pod (FLIR/Charged Coupled Device
camera(CCD)/Laser Designator Target and Ranger (LDTR)), Electronic Warfare,
Identification and Sensor Fusion.
The OSMC Test Bench architecture is shown in
Figure 1 and Figure 2 and it is composed by the following components:
 OSMC: The OSMC equipment is the heart of the system. It is the mission
computer. It is connected to the navigation sensors and the radios through three
1553B buses. It is connected to four displays through RGB and RS-422 lines. It is
connected to the cockpit through discrete lines. The Forward Looking Infra-Red
Camera (FLIR) and RADAR PAL video input the OSMC to be displayed as video
underlay in Left Multifunction Display (LMFD) and Right Multifunction Display
(RMFD) respectively.
 Displays: Five displays (Head Up Display (HUD), Multifunction Up Front Control
(MUFC), LMFD, RMFD and Down Multifunction Display (DMFD)), four color
multifunction displays (MUFC, LMFD, RMFD, DMFD) connected directly to the
OSMC through Video RGB and RS-422 lines. The fifth display (HUD) is indirectly
connected to the OSMC through the Scenario and Flight Simulation PC.
 Scenario and Flight Simulation PC: This PC will run the Microsoft Flight
Simulator. It will be the external scenario and own aircraft flight simulator. All
navigation information will be obtained from this simulation.
 Simulations PCs: There are no real sensors. They are simulated within the
following simulations:

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 Onboard Systems Design
Degree in
Aerospace Engineering PRACTICE “OSMC Test Bench Practice”

Name:

- COMM1 and COMM2 SIM: Two simulations for VHF/UHF Radios.

- RDC1 SIM: Simulation for Remote Data Concentrator 1 (RDC1). It will simulate
the 1553 interface for the RDC1 computer. It concentrates the data to/from the
following simulations:
o Standby ADI SIM,
o ADF SIM,
o TACAN SIM,
o VOR SIM,
o DME SIM,
o ILS SIM, and
o Transponder SIM.
The navigation information will be obtained from the FS2002 Simulation.
- ADC SIM: Simulation for Air Data Computer (ADC). The navigation data will
be extracted from the FS2002 Simulation.
- EGI SIM: Simulation for EGI. The navigation data will be extracted from the
FS2002 Simulation.
- RDC2 SIM: Simulation for Remote Data Concentrator 2 (RDC2). It will simulate
the 1553 interface for the RDC2 computer. It concentrates the data from the
following simulations:
o Fuel SIM,
o Pressures SIM,
o Engine SIM.
The data will be obtained from the FS2002 Simulation.
- FCC SIM: Simulation of the Flight Control Computer (FCC). The data will be
obtained from the FS2002 Simulation and will be prepared and formatted. It also
interfaces data from Hands On Throttle and Stick (HOTAS) simulation.
- Autopilot SIM: Autopilot Control simulation.
- FS2002 SIM: Simulation which is in charge of getting data from the Scenario and
Flight Simulation PC via FSUIPC and putting this information into the shared
memory in the Simulations PC. The sensor simulations will get these data.
- RADAR SIM: simulation for A/A and A/G Radar.
- Target Pod SIM: simulation for Target Pod (FLIR, CCD and LDTR).
- Tactical Data Link SIM: simulation for Tactical Data Link.
- IFF Interrogator SIM: simulation for the Identification Friend or Foe (IFF)
Interrogator.
- EW SIM: Simulation for Electronic Warfare (EW) Equipment (Radar Warning,
Radar Jamming, Countermeasures Dispenser).
 Tactical Video simulations: There will be two-video players outputing PAL video
simulating the video from the FLIR and RADAR sensors.

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Degree in
Aerospace Engineering PRACTICE “OSMC Test Bench Practice”

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 Cockpit discrete lines: There will be some discrete input lines to the OSMC
simulating some pushbuttons in the cockpit panels.
 HOTAS: A commercial HOTAS will be connected to the Scenario and Flight
Simulation PC for piloting the aircraft.
 RIG Configuration discrete lines: Some discrete lines are reserved for
configuration issues.

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 Onboard Systems Design
Degree in
Aerospace Engineering PRACTICE “OSMC Test Bench Practice”

Name:

Ethernet (HUD Video

Commands)

Scenario and Video RGB HUD

Flight
Simulation PC
Video RGB
MUFC RS-422

LMFD RMFD

Video
Video DMF RGB
RS-422
HOTAS RGB D
Video RS-422
Discrete lines RGB
for RIG RS-422
configuration

Discrete lines OSMC SW Loading and

Cockpit
Debugging Line
Ethernet
FLIR/CCD Video PAL Video
RADAR Video
Ethernet

COMM1 COMM2 Simulations PCs

SIM SIM
MUX 1 MUX 3

RDC1 EGI ADC RDC2 FCC A/P

SIM SIM SIM SIM SIM SIM
Shared Memory Shared Memory
FUEL
RADALT ADF TXPR FS2002 HOTAS
SIM
SIM SIM SIM SIM SIM

PRESS
SIM
TACAN VOR DME ILS STANDBY ENGINE
SIM SIM SIM SIM ADI SIM SIM

Figure 1. System Architecture (Basic Avionics).

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 Onboard Systems Design
Degree in
Aerospace Engineering PRACTICE “OSMC Test Bench Practice”

Name:

Ethernet (HUD Video

Commands)

Scenario and Video RGB HUD

Flight
Simulation PC
Video RGB
MUFC RS-422

LMFD RMFD

Video
DMFD RGB
Video
HOTAS RGB
RS-422 RS-422
Video
Discrete lines
RGB RS-422
for RIG
configuration

Discrete lines OSMC SW Loading and

Cockpit
Debugging Line
Ethernet
FLIR/CCD Video
PAL Video
RADAR Video
Ethernet
Simulations PCs
RADAR TPOD
SIM SIM
MUX 2 MUX 3

TDL EW IFF SMS

SIM SIM SIM SIM
MUX 1

Figure 2. System Architecture (Specialized Avionics).

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 Onboard Systems Design
Degree in
Aerospace Engineering PRACTICE “OSMC Test Bench Practice”

Name:

TASK: GENERAL SYSTEMS INTEGRATION

1. INTRODUCTION

The General Systems of the aircraft is composed of Fuel, Engine, Environmental and
Hydraulic systems. Those systems are normally controlled by dedicated computers in
the aircraft, verifying the system health status and taking the appropriate actions on each
case.
The status of the system is provided to the pilot through the avionics buses to the
Mission Computers that translates them into visual information in the displays of the
aircraft cockpit. The format more commonly used on those displays is the Engine-
Indicating and Crew-Alerting System (EICAS) format.
The EICAS format is composed by several clocks to measure information about fuel,
engine and hydraulics ratios. The clocks drawn in this format are the followings:
- N2,
- EGT,
- FF,
- Nozzle,
- Oil Press,
- Hydraulics A,
- Hydraulics B,
- Cabin pressure,
- Oxygen capacity,
- Internal Fuel,
- External Fuel,
- Total Fuel.

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 Onboard Systems Design
Degree in
Aerospace Engineering PRACTICE “OSMC Test Bench Practice”

Name:

2. TASK DESCRIPTION

The objective of the task is to test the EICAS format by stimulating the avionics bus
signals in order to check:
 OSMC detects when EICAS information is not available.
 Check correct mapping of General Systems information in the display
 Verify ranges of each value identified in the display.
 Check one or two engines aircraft configuration.

For this purpose the students shall define a test procedure that verifies the requirements
shown in the following section. The test procedure must contain the following
subsections:
1. Test description.
2. Initial conditions (computer status, simulations status, displays status, controls
status).
3. Test procedure (detailed description of the steps to perform the test) to check the
maximum, the minimum and some intermediate values of the range of
every signal, some out of range values and some values to check the
resolution of every signals:
a. Test inputs: Actions performed by the user on the Cockpit controls or
SEAS input signals.
b. Test outputs: Information displayed in the Cockpit displays or SEAS
output signals.

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 Onboard Systems Design
Degree in
Aerospace Engineering PRACTICE “OSMC Test Bench Practice”

Name:

3. FUNCTIONAL REQUIREMENTS

REQ_EICAS_0001: Number of Engines.

If the aircraft is just one-engine aircraft only will be drawn N2, EGT, FF, NOZZLE
and OIL PRESS clocks for the engine in the left side. If the aircraft is two-engines
aircraft will be drawn N2, EGT, FF, NOZZLE and OIL PRESS clocks for the two
engines in the left side for ENGINE 1 and in the right side for ENGINE 2.
In the case of receiving a not valid value of this signal the default value shall be a
one-engine configuration.

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Degree in
Aerospace Engineering PRACTICE “OSMC Test Bench Practice”

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REQ_EICAS_0002: N2 clock.
This clock measures the N2 Compressor Rotor Speed of the engine aircraft. There
will be a different clock for each engine. If the aircraft is just one-engine aircraft only
will be drawn a clock for the engine in the left side. The possible range is from 0 to
115. Below to the clock shall be written the actual value with the format “ZZ9”.
In the case of receiving a not valid value of this signal the default value shall be
100%.

REQ_EICAS_0003: EGT clock.

This clock measures the Exhaust Gas Temperature (EGT) in degrees of the engine
aircraft. There will be a different clock for each engine. If the aircraft is just one-
engine aircraft only will be drawn a clock for the engine in the left side. The possible
range of the EGT clock is from 0 to 900 in degrees. Below to the clock shall be
written the actual value with the format “ZZ9”.
In the case of receiving a not valid value of this signal the default value shall be
900ºC.

REQ_EICAS_0004: FF clock.
This clock measures the Fuel Flow (FF) of the engine aircraft. There will be a
different clock for each engine. If the aircraft is just one-engine aircraft only will be
drawn a clock for the engine in the left side. The possible range of the FF clock is
from 0 to 99990 in pounds per hour (PPH). Below to the clock shall be written the
actual value with the format “ZZZZ9”.

REQ_EICAS_0005: Oil pressure clock.

This clock measures the Oil Pressure of the engine aircraft. There will be a different
clock for each engine. If the aircraft is just one-engine aircraft only will be drawn a
clock for the engine in the left side. The possible range of the Oil pressure clock is
from 0 to 220 in pounds per square inch (PSI). Below to the clock shall be written
the actual value with the format “ZZ9”.
In the case of receiving a not valid value of this signal the default value shall be
220PSI.

REQ_EICAS_0006: Nozzle clock.

This clock shall be used to indicate the Nozzle position, in percentage. 0 shall be
nearly closed, 100 fully open. There will be a different clock for each engine. If the
aircraft is just one-engine aircraft only will be drawn a clock for the engine in the left
side. Below to the clock shall be written the actual value with the format “ZZ9”.
In the case of receiving a not valid value of this signal the default value shall be
100%.

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Aerospace Engineering PRACTICE “OSMC Test Bench Practice”

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REQ_EICAS_0007: Hydraulics A clock.

This clock shall be used to indicate the Hydraulics pressure in circuit A. The possible
range of the Hydraulics A clock is from 0 to 6000 in PSI. Below to the clock shall be
written the actual value with the format “ZZZ9”.
In the case of receiving a not valid value of this signal the default value shall be
6000PSI.

REQ_EICAS_0008: Hydraulics B clock.

This clock shall be used to indicate the Hydraulics pressure in circuit B. The possible
range of the Hydraulics B clock is from 0 to 6000 in PSI. Below to the clock shall be
written the actual value with the format “ZZZ9”.
In the case of receiving a not valid value of this signal the default value shall be
6000PSI.

REQ_EICAS_0009: Cabin Pressure clock.

This clock shall be used to indicate the Cabin Pressure measured as the altitude
above sea mean in thousands of feet. The possible range of this clock is from 0 to
60.0. Below to the clock shall be written the actual value with the format “ZZ9”.
In the case of receiving a not valid value of this signal the default value shall be
60Kfeet.

REQ_EICAS_0010: Oxygen Capacity clock.

This clock shall be used to indicate the Oxygen capacity measured in percentage. 0
shall be empty oxygen capacity in the cabin and 100 fully capacity. The possible
range of this clock is from 0 to 100.0. Below to the clock shall be written the actual
value with the format “ZZ9”.
In the case of receiving a not valid value of this signal the default value shall be
100%.

REQ_EICAS_0011: Internal Fuel clock.

This clock shall be used to indicate the Internal fuel capacity of the aircraft in US
Gallons. The minimum value of this clock shall be 0 US Gallons and the maximum
value shall be measured of the messages from the Fuel computer, so shall be
different for each aircraft model. Below to the clock shall be written the actual value
with the format “ZZZZ9”.

REQ_EICAS_0012: External Fuel clock.

This clock shall be used to indicate the External fuel capacity of the aircraft in US
Gallons. The minimum value of this clock shall be 0 US Gallons and the maximum
value shall be measured of the messages from the Fuel computer, so shall be
different for each aircraft model. Below to the clock shall be written the actual value
with the format “ZZZZ9”.

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Aerospace Engineering PRACTICE “OSMC Test Bench Practice”

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REQ_EICAS_0013: Total Fuel clock.

This clock shall be used to indicate the Total (internal plus external) fuel capacity of
the aircraft in PSI. The minimum value of this clock shall be 0 US Gallons and the
maximum value shall be measured of the messages from the Fuel computer, so shall
be different for each aircraft model. The red scale to indicate to the pilot danger of
little fuel shall be the bingo level. Below to the clock shall be written the actual value
with the format “ZZZZ9”.

4. INTERFACE REQUIREMENTS (ICD)

The following signals are available in the SEAS test panel EICAS for stimulating the
1553 signals, which shall be used as Test Inputs:

NUMBER OF ENGINES (RDC2_E_NUMBER)

Type: Integer.
Range/Units: 0 to 3. LSB=1.
Comments: This field reports the number of ENGINES.

ENGINE 1 N2 COMPRESSOR ROTOR SPEED (RDC2_E1_N2)

Type: Integer.
Values: 0 to 115%. LSB = 1%.
Comments: This field reports the N2 compressor rotor speed in percentage for the
engine 1.

ENGINE 2 N2 COMPRESSOR ROTOR SPEED (RDC2_E2_N2)

Type: Integer.
Values: 0 to 115%. LSB = 1%.
Comments: This field reports the N2 compressor rotor speed in percentage for the ENGINE
2.

ENGINE 1 EXHAUST GAS TEMPERATURE (RDC2_E1_EGT)

Type: Integer.
Range/Units: 0 to 65535ºC. LSB=1ºC.
Comments: This field reports the exhaust gas temperature for the engine 1 (ºC).
.
ENGINE 2 EXHAUST GAS TEMPERATURE (RDC2_E2_EGT)
Type: Integer.
Range/Units: 0 to 65535ºC. LSB=1ºC.
Comments: This field reports the exhaust gas temperature for the ENGINE 2 (ºC).

ENGINE 1 FUEL FLOW (RDC2_E1_FUEL_FLOW)

Type: Integer.
Range/Units: 0 to 65535 PPH. LSB=1 PPH.
Comments: This field reports the fuel flow for the engine 1 (PPH).

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ENGINE 2 FUEL FLOW (RDC2_E2_FUEL_FLOW)

Type: Integer.
Range/Units: 0 to 65535 PPH. LSB=1 PPH.
Comments: This field reports the fuel flow for the ENGINE 2 (PPH).

ENGINE 1 OIL PRESSURE (RDC2_E1_OIL_PRESS)

Type: Integer.
Values: 0 to 255 PSI. LSB = 1 PSI.
Comments: This field reports the oil pressure in PSI’s for the engine 1 (PSI).

ENGINE 2 OIL PRESSURE (RDC2_E2_OIL_PRESS)

Type: Integer.
Values: 0 to 255 PSI. LSB = 1 PSI.
Comments: This field reports the oil pressure in PSI’s for the ENGINE 2 (PSI).

ENGINE 1 NOZZLE (RDC2_E1_NOZZLE)

Type: Integer.
Values: 0 to 255%. LSB = 5%.
Comments: This field reports the nozzle opening percentage for the engine 1 (%).

ENGINE 2 NOZZLE (RDC2_E2_NOZZLE)

Type: Integer.
Values: 0 to 255%. LSB = 5%.
Comments: This field reports the nozzle opening percentage for the ENGINE 2 (%).

HYDRAULIC CIRCUIT A (RDC2_HYD_A)

Type: Integer.
Range/Units: 0 to 65535 PSI. LSB=1 PSI.
Comments: This field reports the hydraulic circuit A pressure (PSI).

HYDRAULIC CIRCUIT B (RDC2_HYD_B)

Type: Integer.
Range/Units: 0 to 65535 PSI. LSB=1 PSI.
Comments: This field reports the hydraulic circuit B pressure (PSI).

CABIN PRESSURE (RDC2_CABIN_PRESS)

Type: Integer.
Range/Units: 0 to 65535 Kfeet. LSB=1 Kfeet.
Comments: This field reports the cabin pressure (Kfeet).

LOX PILOT’S LIQUID OXIGEN (RDC2_LOX)

Type: Integer.
Range/Units: 0 to 65535%. LSB=1%.
Comments: This field reports the lox liquid oxygen available to the pilot (%).

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INTERNAL FUEL (RDC2_INTERNAL_FUEL)

Type: Integer.
Range/Units: 0 to 65535 US Gallons. LSB=10 US Gallons.
Comments: This field reports the total internal fuel weight (US Gallons).

EXTERNAL FUEL (RDC2_EXTERNAL_FUEL)

Type: Integer.
Range/Units: 0 to 65535 US Gallons. LSB=10 US Gallons.
Comments: This field reports the total external fuel weight (US Gallons).

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Aerospace Engineering PRACTICE “OSMC Test Bench Practice”

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APPENDIX: TEST TEMPLATE

Test Description:

<Introduce here a brief description of the intention of the test and the requirements that are
validated>

Initial conditions:

Assume for all tests the following conditions:

- All SEAS necessary simulations are running.
The RDC2 Simulation is available in the SEAS to simulate the General
Systems Information: Select “RDC2_Simulation”, press the “Run” button
and wait until its state was RUNNING.
- OSMC equipment is running.
- Cockpit displays and HUD are running.
- Test specific stimulation panel is open.

<Introduce here also the initial states of the signals that will be used>

Test Procedure:

Step Action Expected Result

1 <Introduce here actions on cockpit or SEAS <Reflect here expected states in the displays
signals> or signals on SEAS>
2 RDC2_E_NUMBER = 1 Only the clocks related to just one-engine
format will be shown.
3
...

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