Periodic Reporting for period 3 - AMuLET (Advanced Control Unit for Morphing Leading Edge Management)
Période du rapport: 2021-03-01 au 2021-10-31
The topic call addressed is focused on the development of power management unit enhanced with smart control capabilities. The control loop is here defined as “smart” because of innovative acquisition and control strategies required to cope with a large amount of feedback sensed from actuators and leading-edge shape reconstruction sensors.
Therefore, the main objectives of the present proposal are:
1. design and development of a compact control device for Morphing Leading Edge application with the following innovative characteristics:
• reduced dimensions and weight
• smart sensing algorithms
• advanced control laws
• innovative health monitoring strategies
• modular software
• smart power management
2. integration test in relevant environment with the aim:
• to validate the control device w.r.t. functional and performance requirements (at system level)
• to verify and validate the correct integration with scale one actuators
Therefore, the main objectives of the present proposal are:
1. design and development of a compact control device for Morphing Leading Edge application with the following innovative characteristics:
• reduced dimensions and weight
• smart sensing algorithms
• advanced control laws
• innovative health monitoring strategies
• modular software
• smart power management
2. integration test in relevant environment with the aim:
• to validate the control device w.r.t. functional and performance requirements (at system level)
• to verify and validate the correct integration with scale one actuators
Task 1.1 Requirement Capture / System Specifications: In this task the topic manager has provided to the Consortium the technical specifications. The Consortium starting from the given specification produced as output the deliverable D1.1 the AMuLET system Specification, where are defined
• AMuLET project framework component description
• Component physical interfaces
• Data types
• AMuLET function requirements
• AMuLET Hardware requirements
T1.2 Electrical and Mechanical Interface Specification
In this task the specifications related to the mechanical and electrical interfaces have been discussed and defined in collaboration with the Topic Manager, in particular:
- Chassis Space Envelope
- Electrical Interface to the power Bus
- Electrical Interface to the actuators
- Electrical Interface for communication with the ground station
T1.3 Preliminary System Design:
The Design is divided on two boards. Those boards are also divided in functional PCBs. That is done to test each functional PCB previous the final design. The final design will be formed by the two main boards. Those are the Control Unit and the Power Unit.
T2.1 Detailed Design HW (power & control module, housing)
The AMuLET Hardware has been designed from the beginning to be modular. The following two parts have been designed:
• Control Unit, consisting of a ZYNC 7000 FPGA module with an integrated STM32 microcontroller mounted on a PCB with the connections needed for the Unit, such as CAN bus and Analog Inputs and Outputs.
• Power Unit, consisting of various PCBs. Specifically, the Motor Driver, Hall Sensors Acquisition, Supply and CAN Bus PCBs. All together they allow the Motor to move with the commands of the Control Unit, for now, a STM32 Discovery Board.
T2.2 Control Unit & Data Acquisition Strategies: a preliminary software architecture for the AMuLET system has been defined. AMuLET is composed by two main section: a real time section using a FPGA and supervisor section realized for the Linux environment. For each of the two section has been defined all the needed modules and functionalities.
T2.3 System mathematical mode (in course): Following the MBD approach has been realized a model of the software for the real time section in order to be able to simulate the behaviour of the system. To design these components has been used the VIVADO Suite and MATLAB. Some preliminary test of real time SW will be performed on a laboratory prototype.
T2.4 Interface Unit (sensors, emas and ground equip.)
The design includes the following interfaces:
• HALL Sensors acquisition.
• Current and Temperature Measurements. These are for Health Monitoring purposes.
• CAN Bus communication.
• Analog Inputs and Outputs. The Control PCB has 2 6x1 Connectors, for Analog Inputs and Outputs, these are multipurpose connections that can be configured.
• Ethernet. The Control Board includes an Ethernet Connection that allows it to be configured or commanded through local connection.
• USB. The Redpitaya also includes USB and MicroUSB connections, in case needed.
T2.5 Health Monitoring System:
During this task, monitor strategies were identified in order to prevent and reduce the effects of failure modes. A protocol and parameters to be exchanged with external system are defined so to have a reliable control of amulet system.
T3.1 Software Coding and Validation
SW was developed in a suitable environment for “host” platform.
Preliminary verification on “host” computer was conducted starting from requirements designed in WP1 and WP2 in order to verify interfaces, implementation and coverage.
Test activities will be completed with Task 3.3.
T3.2 Components Manufacture or Procurement
HW design tested in T2.1 was improved and manufacturing of the system was done. The final system includes up to four Power Boards and one Control Board, and a suitable case for a 19” rack was selected. The SW needed for the Power Boards was done and a Connection board was designed and manufactured to allow initial testing with the RedPitaya instead of the Control Board. Also, the design of the demonstrator was started. Test activities on the system will be continued in Task 3.3.
T3.3 HW/SW Integration and Verification (in progress)
Initial testing between HW and SW developed by the partners was done, then meetings were held to discuss changes for a smoother integration process on the final system. Topics discussed were:
• Communication protocol between Control and Power Boards.
• Signals that were going to be monitored from the Power Board and sent between Control and Power Boards, to ensure the control loops, adapting to the final motor model selected.
• Inquiries related to the FPGA that was to be installed in the Control Board, related to its programming and pinout, to ensure smooth integration of their SW developed using the RedPitaya as testing unit.
• A new version of the connections board used to connect the RedPitaya with the Power Board was asked for, as integration was going to be done first with RedPitaya to avoid errors.
Final stage of integration will begin once the final system arrives at Italsystems for testing.
• AMuLET project framework component description
• Component physical interfaces
• Data types
• AMuLET function requirements
• AMuLET Hardware requirements
T1.2 Electrical and Mechanical Interface Specification
In this task the specifications related to the mechanical and electrical interfaces have been discussed and defined in collaboration with the Topic Manager, in particular:
- Chassis Space Envelope
- Electrical Interface to the power Bus
- Electrical Interface to the actuators
- Electrical Interface for communication with the ground station
T1.3 Preliminary System Design:
The Design is divided on two boards. Those boards are also divided in functional PCBs. That is done to test each functional PCB previous the final design. The final design will be formed by the two main boards. Those are the Control Unit and the Power Unit.
T2.1 Detailed Design HW (power & control module, housing)
The AMuLET Hardware has been designed from the beginning to be modular. The following two parts have been designed:
• Control Unit, consisting of a ZYNC 7000 FPGA module with an integrated STM32 microcontroller mounted on a PCB with the connections needed for the Unit, such as CAN bus and Analog Inputs and Outputs.
• Power Unit, consisting of various PCBs. Specifically, the Motor Driver, Hall Sensors Acquisition, Supply and CAN Bus PCBs. All together they allow the Motor to move with the commands of the Control Unit, for now, a STM32 Discovery Board.
T2.2 Control Unit & Data Acquisition Strategies: a preliminary software architecture for the AMuLET system has been defined. AMuLET is composed by two main section: a real time section using a FPGA and supervisor section realized for the Linux environment. For each of the two section has been defined all the needed modules and functionalities.
T2.3 System mathematical mode (in course): Following the MBD approach has been realized a model of the software for the real time section in order to be able to simulate the behaviour of the system. To design these components has been used the VIVADO Suite and MATLAB. Some preliminary test of real time SW will be performed on a laboratory prototype.
T2.4 Interface Unit (sensors, emas and ground equip.)
The design includes the following interfaces:
• HALL Sensors acquisition.
• Current and Temperature Measurements. These are for Health Monitoring purposes.
• CAN Bus communication.
• Analog Inputs and Outputs. The Control PCB has 2 6x1 Connectors, for Analog Inputs and Outputs, these are multipurpose connections that can be configured.
• Ethernet. The Control Board includes an Ethernet Connection that allows it to be configured or commanded through local connection.
• USB. The Redpitaya also includes USB and MicroUSB connections, in case needed.
T2.5 Health Monitoring System:
During this task, monitor strategies were identified in order to prevent and reduce the effects of failure modes. A protocol and parameters to be exchanged with external system are defined so to have a reliable control of amulet system.
T3.1 Software Coding and Validation
SW was developed in a suitable environment for “host” platform.
Preliminary verification on “host” computer was conducted starting from requirements designed in WP1 and WP2 in order to verify interfaces, implementation and coverage.
Test activities will be completed with Task 3.3.
T3.2 Components Manufacture or Procurement
HW design tested in T2.1 was improved and manufacturing of the system was done. The final system includes up to four Power Boards and one Control Board, and a suitable case for a 19” rack was selected. The SW needed for the Power Boards was done and a Connection board was designed and manufactured to allow initial testing with the RedPitaya instead of the Control Board. Also, the design of the demonstrator was started. Test activities on the system will be continued in Task 3.3.
T3.3 HW/SW Integration and Verification (in progress)
Initial testing between HW and SW developed by the partners was done, then meetings were held to discuss changes for a smoother integration process on the final system. Topics discussed were:
• Communication protocol between Control and Power Boards.
• Signals that were going to be monitored from the Power Board and sent between Control and Power Boards, to ensure the control loops, adapting to the final motor model selected.
• Inquiries related to the FPGA that was to be installed in the Control Board, related to its programming and pinout, to ensure smooth integration of their SW developed using the RedPitaya as testing unit.
• A new version of the connections board used to connect the RedPitaya with the Power Board was asked for, as integration was going to be done first with RedPitaya to avoid errors.
Final stage of integration will begin once the final system arrives at Italsystems for testing.
AMULET project contributes to and strengthens the leading role of the Europe to combat climate change, fully in line with the objectives of the CLEAN-SKY 2. New morphing technologies may open the door to high performance, environment friendly and economic aircraft operation by better exploiting available weight reduction potentials of new design philosophies without compromising the existing demanding aerospace safety requirements. These technologies are also enabling contributions to sustain or even improve safety of aircraft operation by means of more affordable and efficient integrated sensing / actuating technologies through these new technologies and respective products, Europe will become more independent from the dominant North American aeronautics industry.