Subsystem Interface Testing With Physical and Software Emulation
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Solution Overview
Problem
Conventional systems engineering methods, such as the V model and agile model, often result in interface non-conformances being discovered during final assembly phases of complex systems like aircraft or space vehicles, leading to unplanned time and expense due to the need for corrective actions.
Innovation Solution
A testing system and method that includes a test rig with electrical wiring and mechanical restraints to emulate physical specifications, combined with a virtual software environment to simulate operating software, allowing pre-assembly testing of subsystems to validate interface control documents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If testing is performed after design and building using conventional V model or agile model, then system components can be procured and built according to specifications, but interface non-conformances are discovered during final assembly leading to unplanned time and expense
Solution Approach 1:
The patent applies preliminary action by performing subsystem testing and interface validation before final system assembly. The test rig validates interface control documents and subsystem interactions early in the development process, allowing interface non-conformances to be detected and corrected before they reach final assembly, thereby eliminating unplanned time and expense
Solution Approach 2:
The patent uses a virtual software environment that emulates the operating software as a digital copy or twin of the actual system software. This virtual copy allows testing and validation of interface control documents without requiring the physical system to be fully assembled, enabling early detection of interface issues
2Reliability
If testing is performed after design and building, then complete system can be tested, but interface non-conformances lead to corrective actions during final assembly increasing expense
Solution Approach 1:
The test rig performs preliminary validation of interface control documents and subsystem interactions before final assembly. By testing subsystems individually on the test rig with virtual software emulation, interface non-conformances are identified and corrected early, preventing expensive corrective actions during final system assembly
3Loss of time
If subsystems are tested individually before assembly, then interface issues can be detected early, but additional testing infrastructure is required
Solution Approach 1:
The patent introduces a test rig as an intermediary device between the subsystem and the final system. This test rig includes virtual software that emulates the operating software, serving as a mediator that allows subsystem testing without requiring the complete system to be assembled, thus reducing schedule delays while managing infrastructure requirements
Data Source
AI summary
A testing system and methods of testing interfaces of a subsystem are presented. The testing system is configured to test a subsystem prior to assembly into a system, the testing system comprising a test rig comprising electrical wiring and a mechanical restraint configured to emulate at least one physical specification of the structure; and a virtual software environment developed to emulate operating software for of the system.