THE ARCHITECTURE OF THE F- 35 LIGHTNING II MISSION …F-35 Lightning II MissionSystems Integration...

THEN AND NOW

Dr. Paul E Garrison

Systems Engineer Principal

THE ARCHITECTURE OF THE F-35 LIGHTNING II MISSION SYSTEM

INTEGRATION LAB

© 2019 Lockheed Martin Corporation. All Rights Reserved

BIOGRAPHY SLIDE

Dr. Paul E. GarrisonSystems Engineer PrincipalF-35 Lightning II Mission Systems Integration Labs

Lockheed Martin AeronauticsEmail: [email protected]: 817-763-1494

• Key Programs• Air Force Electronic Warfare Evaluation Simulator• Classified IRAD and CRAD programs• F-22 Raptor Laboratory Simulation• F-22 Raptor Avionics• F-35 Lightning II Mission Systems Integration Laboratory

• PhD in Electrical Engineering• Over 40 years in Hardware in the Loop labs• F-35 HITL Lab Chief Engineer


F-35 MISSION SYSTEMS INTEGRATION LABORATORIES

INTEGRATION LAB CAPABILITY EVOLUTION

• F-35 Variants

• F-35 Avionics Architecture• F-35 Hardware in the Loop (HITL) Laboratories

• Vehicle Systems• Mission Systems

• Stimulation System Integration Station• System integration and test process – then and now

• T&E Evolution• One big lesson learned!• Multi-ship Virtual development Lab (MVDL)

• Success Stories• Lessons confirmed

• Lessons Learned• The future


THE F-35 IS PRODUCED IN THREE VARIANTS – COMMON AVIONICS

STOVL

CV CTOL

Lift FanRoll Nozzle

3-BearingSwivel Duct


By mid-2019: over 370 aircraft, over 200,000 flight hours, more than 840 pilotsand 8,040 maintainers operating from 19 bases around the world

CV – Carrier VariantCTOL – Conventional Takeoff and LandingSTOVL – Short Takeoff/Vertical Landing

SITUATIONAL AWARENESS IS ACCOMPLISHED THROUGH SENSOR DATA FUSION


RADAR

EW

CNI

EOTS

DAS

Image Proc.

Signal Proc.

Fusion Proc.

FireControl& Stores

External Comm.

Data Collect.

Prognostic Health Mgmt.

Mission

Pilot Vehicle

Interface

Integrated Core Processor (ICP)

Sens

or A

pert

ures

Sensors Vehicle SystemsVehicle Mgmt.

Computer A

Vehicle Mgmt.

Computer B

Vehicle Mgmt.

Computer C

VMS

Subs

yste

ms

VMS

Subs

yste

ms

VMS

Subs

yste

ms

Mission Systems HMD

Reports, Tracks, Images

Reports, Tracks, Images

F-35 Lightning II Avionics Architecture

EW – Electronic Warfare, CNI, Communication, Navigation and IFF, DAS – Distributed Aperture System, EOTS – Electro-Optical Targeting System

F-35 LAB PRODUCT DEVELOPMENT “V”


System Definition System andSubsystem Design Implementation Subsystem

TestingSystem Integration

and Test

Detailed Design

Software Development

Software Test

Operational ConceptDevelopment

System Requirements

Preliminary Design

Detailed Design Unit Test

Integrated System I&T

Verification Testing

Desktop Based Simulation (DBS)

Vehicle System Processing/Flight Control

System Integration Facility (VIF)

Ownship Sensors (OSS)Fire Control & Stores

Flight Test

CSCI Integration

Reprogramming Labs

88% of Anomalies are found prior to flight test

F-35 VEHICLE SYSTEMS INTEGRATION LABS


VIF-Fixed Base (FB) Simulator• Purpose: Flight Control Systems

Integration and Test• Retired after SDD program

VIF-Motion Base (MB) Simulator• Purpose: Flight Control Systems,

Handling Qualities and Control Law evaluation Integration and Test

VSIF• Purpose: Integration of Vehicle

Systems: Environmental Control System, Propulsion, Electrical Power, Hydraulics, Failure Modes & Effects Test, VS SW test and integration

Vehicle Systems Labs are Transitioning to a Sustainment role

F-35 MISSION SYSTEMS INTEGRATION LABS


Desktop Based Simulation (DBS)Description: PC-based Software Development StationOperational Flight Program (OFP) Development

Display Development Station (DDS) for Display Software Development

Open-Air System Integration Station (OASIS)Description: All mission systems avionics operating through aircraft apertures, Cockpit controls and displays in lab area.Installed end-to-end system integration and testing.Pole Model retired; Open-Air test capability retained

Simulation System Integration Station (SimSIS)Description: Aircraft ICP integrated with simulated sensorsSupports System Builds and software integration

SimSIS+ adds VS and MS hardware for air-worthiness testing

Stimulation System Integration Station (StimSIS)Description: All Mission Systems Avionics minus the sensor apertures, ICP, Cockpit Controls and DisplaysSystem Integration and Test; Sensor fusion

Sensor Stimulators

RADARCNI

DAS

EW

F-35 STIMULATION SYSTEM INTEGRATION STATION - STIMSIS


Sensors are stimulated at the fidelity required for sensor data fusion testing.

T&E EVOLUTION

SI&T EVOLVED TO EMPHASIZE SHIFT-LEFT

TESTING

• What was retired:• Air System Integration Facility (ASIF) – Limited use of

integrated MS & VS labs due to security constraints• Vehicle Systems Fixed Base Simulator – Capability

retained in the Motion-Based Simulator• Sensor Integration Platform (OASIS Pole Model) –

Open air capability retained using roof-top apertures• Cooperative Avionics Test Bed (CATB) – retired.

• What was re-purposed: Simulated System Integration Stations (SimSIS)

• Air-Vehicle-Air Worthiness Labs: AVOIDS & Sim+• Partner Weapons integration lab• Filled the gap created by the limited utility of the ASIF

• What was added:• A second StimSIS• Multi-ship Virtual Development Lab (MVDL)• Virtual Wingman


AVOIDS - Air Vehicle Optimal Integration Development System

SimSISSimSIS

F-35 MISSION SYSTEMS INTEGRATION – THEN AND NOW


DIS SimSIS

StimSIS

ASIF FlightTest

Domain Integration

Station

Stimulator System

Integration Station

Air System Integration

FacilityOASIS

Open-Air System

Integration Station

Supplier Labs

MVDL SimSIS

StimSIS

FlightTest

Multi-ship Virtual

Development Laboratory

Simulation System

Integration Station OASIS

Supplier Labs

Sim+

AVOIDS - Air Vehicle Optimal Integration Development System

AVOIDS

Air Vehicle Integration

Labs

Simulation System

Integration Station

StimSIS2

ONE BIG LESSON LEARNED – SHIFT LEFT TESTING!


System Definition System andSubsystem Design Implementation Subsystem

TestingSystem Integration

and Test

Detailed Design

Software Development

Software Test

Operational ConceptDevelopment

System Requirements

Preliminary Design

Detailed Design Unit Test

Integrated System I&T

Verification Testing

Desktop Based Simulation (DBS)

Vehicle System Processing/Flight Control

System Integration Facility (VIF)

Ownship Sensors (OSS)Fire Control & Stores

Flight Test

CSCI Integration

Reprogramming Labs

88% of Anomalies are found prior to flight test

MVDL is a key enabler for shift-left testing.

MULTI-SHIP VIRTUAL DEVELOPMENT LABS (MVDL)

A GREAT EXAMPLE OF SHIFT-LEFT TESTING!

• Derived from the Verification Simulation (VSim)• Composed of:

• Simplified Cockpit, controls, and displays• Server-based computer system

• Virtual environment• Capable of simulating eight-ship mission• Mission systems sensor M&S• Vehicle systems M&S• Rehosted ICP, DMC, and AMS

• As M&S became more available and matured, the MVDL was used for Mission Systems I&T

• Software delivered to MVDL• Rapidly tested using automated test tools• Tested prior to introduction to large complex HITL

venues (StimSIS)

A second MVDL has been included as part of an agile development environment


SUCCESS STORIES• Stimulator Labs (StimSIS)

• Initially the value was questioned.• The integration all of the stims/PME together was a great success• The users requested a 2nd StimSIS.• Both StimSIS 1 and StimSIS 2 have the highest utilization of all of the Mission

Systems Labs.• INS/GPS testing. In the lab, we flew the F-35:

• Across the equator• Across the prime meridian• Across the international date line• Over the north and south poles

• 88% of anomalies are found prior to flight test• MVDL was not in our original plan for Mission Systems I&T

• MVDL has proved invaluable for early defect detection• This will be part of OFP development & test as we move forward.

• Vehicle Systems Labs – Electrical Power Systems (EPS) lab F-35 RADAR in-rush current testing


WE CONFIRMED A FEW THINGS

What were we thinking? What are we thinking? Lesson ConfirmedLegacy program had difficulty collecting and analyzing avionics data

F-35 HITL labs were designed with data acquisition in mind & tools were developed

Yes – Some tools are used from software development through System I&T

Legacy program realized that severe anomaly resolution required integrated testing in the HITL lab

Integrated testing – even if SPAR resolution for a single sensor

Yes – Integrated testing

Legacy program had no way to perform stability testing

Labs have the ability to run and stimulate multiple sensors for extended periods of time

Yes – stability testing is required in an integrated lab environment

Single sensor testing is adequate Re-learned the lesson that single sensor testing is just the beginning

Integrated testing – Test Like You Fly (TLYF)

Legacy Program labs were scattered geographically limiting the ability to perform full system integration

Program labs are collocated in Ft. Worth Yes – Mission Systems Labs, Vehicle systems labs Man-in-the-loop labs in FW


WE LEARNED A FEW THINGS


What were we thinking? What are we thinking? Lesson LearnedSeparate Virtual and HITL labs Integrated Virtual and HITL labs Use virtual test environments to mature

software before HITL testing

Deliver Models and Simulations after the capability has been delivered

Deliver models and simulations as soon as possible before capability is delivered

Use virtual test environments to mature software before HITL testing

Integrate separate MS and VS labs for Air-Vehicle testing

Need a single integrated MS & VS lab Integrated systems need to be tested in an integrated environment

Mission Systems subsystems can be tested separately

Mission Systems subsystems cannot be tested separately

Integrated systems need to be tested in an integrated environment

We can save money by deleting capabilityfrom the test lab

You will not save money removing capability from a lab

In the long run you will not save money byreducing lab capability

Labs can be used 24 X 7 Labs cannot be used 24 X 7 Unless the lab configuration is stable, upgrade and maintenance shifts are needed: 25% of prime time shifts.

Technology Refresh is planned for the end product but not for the labs

Labs also require tech refresh Lab systems are subject to diminishing Manufacturing sources and out-of-production parts – same as the end product

Labs will be scheduled 24 X 7 only for short periods of time (surge capacity).

Labs that are run 24 X 7 (over-utilized) suffer from reduced efficiency.

Lab cannot be used 24 X 7 for extended periods of time.

THE FUTURE…

INCREASE THE ROLE OF VIRTUAL SIMULATION IN THE

SOFTWARE DEVELOPMENT AND TEST PROCESS

• Shift Testing Left• Identify tooling and process changes that allow OFP

testing to naturally occur sooner in the development lifecycle

• Shift defect detection left out of lab and flight testing.• Increase maturity of SDLs before lab and flight testing

• Improve OFP Software Development Tools• Identify tooling and process changes that lower cost by

making each lab user more efficient and effective• Requirements force us to assess ‘high impact changes’

– not minor tweaks

• Improve Overall Lab Efficiency• Identify lab product and lab process improvements

that will reduce the overall cost while maintaining or increasing product quality

• Demonstrate capability maturity in lab testing and reduce the number of times a function is tested

• Make common automated test tools available throughout the software development process

• Integrate virtual and hardware in the loop development and test environments – F-35 Virtual Wingman.


F-35 INTEGRATION LAB EVOLUTION

NEW TEST AND EVALUATION LESSONS WERE LEARNED

AND OLD LESSONS CONFIRMED.

• The F-35 Lightning II Mission Systems Integration Labs have evolved since they were described in 2003.

• Many of the development, test, and evaluation venues were repurposed due to the late availability of models and simulations.

• The multi-ship virtual development lab (MVDL) was developed late in SDD.

• It is a key enabler of shift-left testing.• It relies on models and simulations for software

development in an agile environment.• It is used from software development through

software integration and test. • The MVDL is the future of F-35 Lightning II

mission systems integration and test.


WHAT QUESTIONS DO YOU HAVE?



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