EXPO 2017 Airbus MBSE PDF

Model‐Based Design for Fuel
System Development
Christopher Slack, Airbus

04 October 2017
54,000 €49.2billion 6,726 400
Employees Annual revenue* Backlog Operators
17,287 60 10,561 25,000+

Aircraft sold Produced monthly Delivered Daily flights
2 4th October 2017 MATLAB EXPO - Model‐Based Design for Fuel System Development
System Development Perimeter and Interfaces
Air to Air Flammability Reduction
Refuelling
Flame
arrestor
Fuel Pumps Burst Discs
Pipes, Couplings
Engines Refuel Panel

POWER SUPPLY SHUTOFF
L OUTR FEED 1 FEED 2 FEED 3 FEED 4 R OUTR TEST
OPEN BATTERY
NORMAL
SHUT
HI LVL
L OUTR FEED 1 FEED 2 FEED 3 FEED 4 R OUTR ACTUAL (FOB) FAULT OVERFLOW
4000 20800 21840 21840 20800 4000 201000 kg
AUTO REFUEL
27120 19860 13740 0 19860 27120 211000 kg
L MID L INR TRIM CTR R INR R MID PRESELECT (PFQ) STATUS
HI LVL
OPEN OFF APU EMERGENCY

MAN AUTO INCREASE
REFUEL REFUEL
Cockpit displays
SHUT
DEFUEL DOWN
SHUT
L MID L INR TRIM CTR R INR R MID DECREASE
XFR
REFUEL / DEFUEL VALVES MODE SELECT PRESELECT
Valves
Fuel Gauging
& Control
Computers Compensators
Densitometers
Electrical Gauging
Interfaces Fuel Probes Level Sensors Temp
Sensors
Model Use History Model Based System Engineering
Model Based Design
A350
Model Based Design
(Amount / Fidelity)
A400M Fuel Virtual

Use of models
Integration
V&V Auto Test Platform
Model Based A380 & SLDV
V&V
Model Based Design
Desktop simulator
Textual A340-600
Textual Requirements
Textual Functional
Requirements
Requirements
Requirement
Validation
A330/A340
Iron Bird
A320
A300 Specific,
Targeted V&V
CofG Calcs Time
MATLAB, Matrix-X, MATLAB, MATLAB, MATLAB, SysML, MATLAB, Simulink,

Fortran, Easy5, Simulink, Simulink, RTW, Simulink, Stateflow, SLDV,
HP Basic Statemate Statemate Stateflow Stateflow, SLDV Simscape, …
Towards Full MBSE
System Requirement Authoring, Validation and Verification
Model Based Design Lifecycle
MG3 MG5 MG7 MG9 MG11
Tank Modelling:
A/C - Output for Gauging & Fuel
Management Architecture
Mission Distribution
AMO & FSP Aircraft 0
Inerting Certification 16
- Output for Wing design (stress, load, 14
for Test Rig
Number of Mission in 200 nm block

Design
12
using Modelling 10
etc.) 8
6
and A/CO
4
00
00
00
00
00
00
00
00
00
0
00
10
20
30
40
50
60
70
80
90
10
Range 1000's NM
Multi-systems
Fluid and
Thermal
Detailed Integration
modelling
Design Testing
Matlab Simulink for Fuel

Management SSRD
FVIP
Systems Req and detailed design Simulation Fuel Virtual Integration
Platform to support
system tests
Desktop Simulator
Desktop simulator for Suppliers s/w dev
Validation of requirement
Equipments
and Verification of detailed
design Model translation for software
development
Model Based Design - In Practice
voice
& voice
TOP LEVEL REQ

data
&
Environment data 3D positions
Develop models to specify system functionality

– Describes behavioural & functional aspects SATCOM HF / VHF Air Traffic Control Radar
Radar network
SITA/ARINC network
Details become the System (and Sub-System)

Requirements
– Exercise the model to Validate FUNCTIONAL/
SYSTEM REQ
Requirements
Delivered to Fuel System Supplier
– Model contains Requirements and intent
– Model execution provides system LOW LEVEL
EQUIP REQ
understanding
– Minimal Work to turn into Code
– Separate layer for independent validation
LOW LEVEL
EQUIP DEV
Page
MBSE – Functional System Requirements
• MATLAB/Simulink/Stateflow Application
• Development of Control System Reqts
– Normal and Failure Operating Modes
– Crew Procedures
• Control Logic separated from Aircraft Environ
– System Designers focus on
– Control Functions
– HMI
– Robustness & Validation
– Specialist Modellers focus on:
– Aircraft & Environmental Simulation
– Physics (Fuel, Thermal)
– Auto-Test Capabilities
MBSE – Stateflow for Requirements Authoring
• Aircraft Fuel System Statecharts:

• Linked Requirements
– System Requirements Documents Cascade
– Requirements Database (DOORS)
• Separate Chart for each Major A/C Function
– Allows for collaborative development
• Transition booleans calculated externally
– Input from Simulink
– Stateflow graphical function
• Driven behaviour of Stateflow logic separated from
driving conditions
– Allows easier readability and testing
Model Based Design - Reuse
• Integrated Desktop Simulator

– Requirements & Environment Model
– AutoCode using Simulink Coder
– Optional Interfaces to Cockpit Display & Flight Warning
• OCASIME, VIP & Aircraft -1
– Entire Software Simulation
– Interfaces Identical to Full Flight Simulator
• Aircraft-0 (Iron Bird)
– Cockpit Avionics & Displays
– Integrated of Real & Simulated Systems
– Virtual Hosting of Supplier’s Code
• Full Flight Simulator
– Single model for all platforms
– Training Flight and Ground Crews
Model Development Test/Verification/Validation Cycle Test Objective
Validation
• Model V&V has to go through several loops
– When the model is the requirements, the distinction Test Script
Validation
between “Model Verification” and “Requirements
Validation” is somewhat blurred Test Test
Objectives Scripts
If a test fails, what is at fault?
– the requirement?
– the model?
Model Results &
– the test? Requirements MODEL
Specification Problems
Model
Environment Verification
Model
Validation
Requirement
Validation
Using Simscape to Model A350 Refuel System
Component export, parameter estimation
And model simplification for Real Time performance
Use of Simscape
• Fuel Design Model Developed in Flowmaster Flowmaster Diagram

– Architecture and Component Performance
– Spec Model Only - not real-time
– Cannot produce C-Code or embedded simulations
• Exploiting new SimHydraulics Toolbox
• Mathworks Consultancy
– Airbus provision of core models and perf data
– Majority of development by Mathworks
Component Development
• Mapping of Flowmaster components to

Simscape/ SimHydraulics equivalents
– Most 1:1 equivalents
– Some required customisation from base library
• Curve Fitting Toolbox

– Fit source data to SimHydraulics block equations
– Saved as Matlab Script for re-use
Library Construction and Parameterisation
System Library
Component Library
• Component Library to customise standard

Hydraulic Library Components
• System Library contains “System Level”

Components
System Palette
• Each System Palette contains Multiple
Components
– E.g. There are several different type of pumps
• System Palette constructed using MATLAB

scripts
– Self Documenting
– Re-run if design model updated
Model Simplification
• Design Model has ~900 individual Components

– A reduction of the number of blocks by a factor of 10 can potentially yield a simulation speed improvement by a factor of 1,000.
• Reduction Strategies
– Reduce multiple serially Connected Pipes/Bends/Losses to a single Equivalent pipe/loss combination
• Design Optimisation toolbox

– Established Equivalent Parameters
• Reduction in the number of components

– Pipe components reduced from 290 to 60
– Total Components reduced from 900 to 170
– So would expect ~120 x speed-up
Model Reduction
• During Refuel or Defuel, certain valves are not in use

– Fluid network behind those closed valves do not contribute to pressure/flow calculations
– Therefore can be removed
Reduced Model
Complete Model
Refuel from
Left Wing
Only
• This can be repeated for each combination of tank that needs to be studied.
– The reduced model can be constructed automatically with MATLAB scripts that analysis network topology.
Simscape Summary of Results
• Two system-level models of the Defuel system created in

SimHydraulics
– One complete: all components required to model the system
behaviour included
– One simplified: all “isolated” components located behind closed
valves removed
• Performance of the simplified model sufficient for real-time
– Tested with Simulink Real Time on industrial PC
• Performance of the complete model not sufficient for real-time
implementation, despite simplifications made.
– Depends on the solver chosen to a large extent
– Improves substantially from with later Simscape versions
– Near real-time performance in exploiting Simscape local solver
• New blocks and demos added to SimHydraulics as a direct result of this
work
Code Efficiencies and Performance Enhancement
Fuel Temperature Prediction Software
Sky Night/Day
Fuel Temperature Prediction for Airlines T∞
Solar radiation
An Exercise in Code Efficiencies Convection
Radiation network Emissivity from skin
Inter-tank Buoyancy
Fuel Transfer external heat
source / sink
Conduction
Emissivity from skin
Heating from earth
T∞ Earth
Comparison of Predicted and Measured Fuel Temperature
30
20
10
Temperature (°C)
0
0 1000 2000 3000 4000 5000 6000 7000 8000
• Low outside temperatures with long exposure times -10
• Fuel temperature may drop close to or below freezing point -20
– Software written in MATLAB

– Predict fuel temperatures given Flight Profiles & Global Air
-30
Temperatures. -40
20 4th October 2017 MATLAB EXPO - Model‐Based Design for Fuel System Development Distance (nm)
Fuel Temperature Prediction for Airlines
An Exercise in Code Efficiencies
Intended Usage
Y
Fuel Cold
N
Fly
Flight Plan Temperature Fuel? Route
Prediction
Run-Time ~ 40 seconds (reasonable)
Actual Usage
Flight Plan Other Safety &
Flight Plan Economic Calculate
Flight Plan Factors Fly
Flight Plan Fuel “Best” Route
Flight Plan Temperature Route
Flight Plan Prediction
Flight Plan
Flight Plann
Up to 50 potential Routes Run-Time ~ 50 * 40 seconds = Half Hour…BAD!

Using MATLAB Profiler to Identify Code Efficiency Bottlenecks
• Exploit MATLAB Profiler

• Built into MATLAB
profile on ; run program ; profile viewer
• Creates timing profiles of every function called
• Look at the “Self Time” for time spent within function
• Profile Report highlights most expensive L.O.C.
• Iterative process to increase code efficiencies.
Code Optimisation Strategies
Run-Time Improvements of Fuel Temperature Prediction Module
40
• Equation Vectorisation
Average Simulation Time per Flight (s)

35
• Loop Unrolling
30
• Switch…case statements
25
– Reduce volume of code inside each “case”
20
• Use c-mex for time-critical functions
– Check target platforms
15
• Minimise Globals 10
– Very slow in MATLAB
5
• Reduce calculations inside for loops Target Time
– Pre-calculate invariant parts of equations 0
May Jun Jul Aug Sep Oct
Keeping Track of Mathworks Release Cycles
Industry Model Testing
Industry Model & Code Testing
Models
• Aircraft Development 3-5 years, Mathworks upgrades every 6 months 1
Valves
2
Modes
Engine Burn
APU Burn
[V]
[M]
Engine Burn
AFSME
Airbus Fuel System Modelling Environment
Flow Rates
10
Program AFSME 3.2 STR 465
Date: Fri Jan 18 11:24:10 2002
Ref: SCF/SYS/GEN/61/2623 Iss. 6
User Guide: SCF/SYS/GEN/61/2909
– One solution to reduce cost of (continuing) upgrade cycles

APU Burn [F]
Mass
Mass Recirc Flow Recirc Rate
Flow Rates Flow Rate Volume Density 5
Jettison 1 Valve States
Jettison Leak Leak Rate Tank Empty
Altitude 2 Transfer Mode Vol 2 Mass
Leaks
IRP_MODE_SELECTIONTanks 5.1.(1)
Altitude Simulation.Temperature
Pitch Tank Empty Enable Temperature
Roll Valves_2_Flowrates
Volumes 5.1.1.(1)
GROUND_OPS/ Temp 1
4 Recirc_Inhibit
Mach Mach Temperature 9
Recirc Inhibit 5.1.3.(1) 5.1.2.(1) 5.1.4.(1)
function evaluate_conditions() 5.1.(2)
Air Temp MANUAL_REFUEL Air Temp AUTO_REFUEL TRANSFER
{
• Testing infrastructure utilising customer models and MATLAB scripts

FP Mux AR= ...
[DELAY(D_GOS)][((AR | XFER |... Temperature
[AR &... &...[XFER&...
DELAY(D_GOS)] [(~GND_SURGE_RELIEF_ACTIVE
Mass
IRP_MODE[IRP_AUTO_REFUEL] & ...
~IRP_MODE[IRP_MANUAL_REFUEL] & ... DF | IDLE) &... DELAY(D_GOS)]
Flight_Profile ~IRP_MODE[IRP_TRANSFER] & ...
~IRP_MODE[IRP_DEFUEL] & ... ~GND_SURGE_RELIEF_ACTIVE) |... ~AR) | SOT_INITIATED]
~IRP_MODE[IRP_OFF] &...
~SOT_INITIATED;
MR_ SOT_INITIATED] AR_ Temperature[~XFER ... TR_
Simulation.CG CONF CONF | SOT_INITIATED] CONF
XFER= ...
Enable CG Calc
IRP_MODE[IRP_TRANSFER] & ... [F]
~IRP_MODE[IRP_MANUAL_REFUEL] & ...
~IRP_MODE[IRP_AUTO_REFUEL] & ...
[MR | FAULT]/d_i=0; [~MR] Flow
[AR]/d_i=0; [~AR] [~XFER] [XFER]/d_i=0;
~IRP_MODE[IRP_DEFUEL]
XCg & ...
~IRP_MODE[IRP_OFF] &... 3 [V] Valves
~SOT_INITIATED &...
XCg
GUIs
~GND_SURGE_RELIEF_ACTIVE;
Pitch
DF= ... Targ_Cg 4 [M]
IRP_MODE[IRP_DEFUEL] & ... Modes
~IRP_MODE[IRP_MANUAL_REFUEL] & ... Targ Cg
~IRP_MODE[IRP_AUTO_REFUEL] & ...
Mom X& ...
~IRP_MODE[IRP_TRANSFER] 6
~IRP_MODE[IRP_OFF] &... Flight Profile
Roll Mom X
– Release Compatibility
~SOT_INITIATED &...
~GND_SURGE_RELIEF_ACTIVE;
Mom Y 7 [DF]/d_i=0; [Mode_Status[TR_SOT_EXIT] &... [~IDLE] [IDLE]/d_i=0;
IDLE= ...
IRP_MODE[IRP_OFF] & ... Mom Y [~DF] ~GND_SURGE_RELIEF_ACTIVE]
CG
~IRP_MODE[IRP_MANUAL_REFUEL] & ...
~IRP_MODE[IRP_AUTO_REFUEL]
Tot Weight & ... DF_ OFF_
~IRP_MODE[IRP_TRANSFER] & ... 8 3 Aux
Mass
~IRP_MODE[IRP_DEFUEL] &... Tot Weight CONF CONF
~SOT_INITIATED &... Auxiliary Plot
~GND_SURGE_RELIEF_ACTIVE; [DF &... [SOT_INITIATED] [IDLE &...
CG Mux
[~DF | SOT_INITIATED] [~IDLE ...
MR= ... DELAY(D_GOS)] Time Plotting| FAULT | SOT_INITIATED ] DELAY(D_GOS)]
Cg_Calc
IRP_MODE[IRP_MANUAL_REFUEL] & ...
~IRP_MODE[IRP_DEFUEL] & ...
~IRP_MODE[IRP_AUTO_REFUEL] & ... 5.1.5.(1) 5.1.6.(1)
~IRP_MODE[IRP_TRANSFER] & ...
~IRP_MODE[IRP_OFF] &... DEFUEL
~SOT_INITIATED; SOT OFF
FAULT= ...
~AR & ~XFER & ~DF & ~IDLE & ~MR;
}
function
– Performance
GO_D = DELAY(d_t)
Tests & Results

5.1.7(1)
SURGE
Win-Win Situation:
• Value to Customers
– Reduced product upgrade cost
– Increased productivity
– Early knowledge of regression ITAR Rated Firewall
• Value to Mathworks
– Compatibility testing Secure Models
Server
– Performance testing Models
– Increased tool adoption

Simple 4-step process
Establish Package Send Review and
NDA Models/Scripts Package Act on Results
Summaries and Lessons Learnt
Lessons Learnt
• Deployment of MBSE • System Designers Focus on Designing the System
– As much about Competences as Technologies – The System Model is the System Requirements
– Skillsets & Mindsets – Extra functionality required to exercise the model are not
– Integration of Functional & Non-Functional models requirements
– Need to clearly identify what are requirements and what
• Model Build Reveals Emergent Properties are the extras
– Validation for free
• Model Architecture
– System difficult to model will be difficult to build/test
– Must match System Architecture
• Validation/Verification Testing – Also conducive to multi-team development
– A test that is more complex than that being tested is
probably wrong • Easy for Designers can be Difficult for Simulators
– Easy to be caught in the trap of “Test for Success” – Engineers can be very “ingenious”
– Testing for intentional but not unintentional – Break downstream processes
behaviour – Model exchange with suppliers
– Automated Test/Analysis allows regression testing – Automatic code generators
– Formal Proof more thorough than test scripts – Require adherence to Style Guidelines and Design Patterns
Thank you
©AIRBUS 2017 All rights reserved

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Model‐Based Design for Fuel

Christopher Slack, Airbus

17,287 60 10,561 25,000+

Fuel Pumps Burst Discs

Engines Refuel Panel

4000 20800 21840 21840 20800 4000 201000 kg

OPEN OFF APU EMERGENCY

REFUEL / DEFUEL VALVES MODE SELECT PRESELECT

Model Based Design

A400M Fuel Virtual

MATLAB, Matrix-X, MATLAB, MATLAB, MATLAB, SysML, MATLAB, Simulink,

- Output for Wing design (stress, load, 14

for Test Rig

Number of Mission in 200 nm block

Matlab Simulink for Fuel

TOP LEVEL REQ

Develop models to specify system functionality

Details become the System (and Sub-System)

• Aircraft Fuel System Statecharts:

• Integrated Desktop Simulator

• Fuel Design Model Developed in Flowmaster Flowmaster Diagram

• Exploiting new SimHydraulics Toolbox

• Mapping of Flowmaster components to

• Curve Fitting Toolbox

• Component Library to customise standard

• System Library contains “System Level”

• System Palette constructed using MATLAB

• Design Model has ~900 individual Components

• Design Optimisation toolbox

• Reduction in the number of components

– So would expect ~120 x speed-up

• During Refuel or Defuel, certain valves are not in use

• Two system-level models of the Defuel system created in

• Low outside temperatures with long exposure times -10

• Fuel temperature may drop close to or below freezing point -20

– Software written in MATLAB

Up to 50 potential Routes Run-Time ~ 50 * 40 seconds = Half Hour…BAD!

• Exploit MATLAB Profiler

Average Simulation Time per Flight (s)

– One solution to reduce cost of (continuing) upgrade cycles

• Testing infrastructure utilising customer models and MATLAB scripts

Tests & Results

– Increased tool adoption

©AIRBUS 2017 All rights reserved

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