EADS/LFK-Lenkflugkoerpersysteme GmbH develops missile systems for a wide field of military applications. The Hardware-in-the-Loop (HWIL) facility of LFK in Unterschleissheim uses a five axis motion simulation table, an IR scene projection system and powerful simulation computers. The system is designed for test and evaluation of different missile programs fitting the dimensions of the five axis table and it's dynamic performance.
Development, configuration management and maintenance of HWIL applications are time and cost consuming processes. Current missile programs are very complex and the development of modern missile systems has to be completed within short time intervals. Programming of HWIL as a test bench is getting a very complex and a high sophisticated task, which runs usually parallel to the missile development process. Programming of HWIL applications, despite physical missile models, means in the most cases low level programming of control loops, state machines, communication tasks, device drivers and integration of physical models. Hard requirements on the faultless functionality and on the accurate real-time behavior make the development and the test of HWIL software an ambitious and complex software development project. So new generation software development methods dealing with complex systems for HWIL applications are needed to shorten the development time, to lower the costs, to simplify the test and to reach a faultless functionality.
LFK-Lenkflugkoerpersysteme GmbH develops missile systems for a wide field of military purposes. The Hardware-in-the-Loop (HWIL) facility of LFK in Unterschleissheim uses a five axis motion simulation table and an IR scene projection system. The system is designed for test and evaluation of several missile programs due to the dimensions of
the five axis table and it's dynamic performance /1/. In a certain cruise missile program there was the need for system tests with nearly all components of the missile as well as special investigations and validation trials for the subsystem consisting of the IR-seeker and the image processing computer. The components had also to pass their qualification tests with the assistance of the HWIL team. These tests and their analysis are focussed to the mechanical accuracy of the gimbals and resolvers of the IR seeker and the tracking accuracy of the image processing computer. Before starting tests in the HWIL it is absolutely necessary to identify errors caused by mechanical tolerances of the test equipment (e.g. mounting of the seeker and the IR projection system) on the five axis motion simulator. Otherwise the obtained test results includes these errors and lead to incorrect system performance evaluation. There are different mechanical errors in mounting which can occur are analysed below. The main problem is caused by possible shifts of the IR-seeker in a plane perpendicular to the optical axis (with gimbals in zero position). Therefore a procedure has been developed using IR test images, a frame grabber and image processing routines to determine the
mounting failures. These can be corrected by using mechanical adjustment tools designed and realised for this purpose.
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