Design and verification of Guidance, Navigation and Control systems for space applications

In the last decades, systems have strongly increased their complexity in terms of number of functions that can be performed and quantity of relationships between functions and hardware as well as interactions of elements and disciplines concurring to the definition of the system. The growing complexity remarks the importance of defining methods and tools that improve the design, verification and validation of the system process: effectiveness and costs reduction without loss of confidence in the final product are the objectives that have to be pursued. Within the System Engineering context, the modern Model and Simulation based approach seems to be a promising strategy to meet the goals, because it reduces the wasted resources with respect to the traditional methods, saving money and tedious works. Model Based System Engineering (MBSE) starts from the idea that it is possible at any moment to verify, through simulation sessions and according to the phase of the life cycle, the feasibility, the capabilities and the performances of the system. Simulation is used during the engineering process and can be classified from fully numerical (i.e. all the equipment and conditions are reproduced as virtual model) to fully integrated hardware simulation (where the system is represented by real hardware and software modules in their operational environment). Within this range of simulations, a few important stages can be defined: algorithm in the loop (AIL), software in the loop (SIL), controller in the loop (CIL), hardware in the loop (HIL), and hybrid configurations among those. The research activity, in which this thesis is inserted, aims at defining and validating an iterative methodology (based on Model and Simulation approach) in support of engineering teams and devoted to improve the effectiveness of the design and verification of a space system with particular interest in Guidance Navigation and Control (GNC) subsystem. The choice of focusing on GNC derives from the common interest and background of the groups involved in this research program (ASSET at Politecnico di Torino and AvioSpace, an EADS company). Moreover, GNC system is sufficiently complex (demanding both specialist knowledge and system engineer skills) and vital for whatever spacecraft and, last but not least the verification of its behavior is difficult on ground because strong limitations on dynamics and environment reproduction arise. Considering that the verification should be performed along the entire product life cycle, a tool and a facility, a simulator, independent from the complexity level of the test and the stage of the project, is needed. This thesis deals with the design of the simulator, called StarSim, which is the real heart of the proposed methodology. It has been entirely designed and developed from the requirements definition to the software implementation and hardware construction, up to the assembly, integration and verification of the first simulator release. In addition, the development of this technology met the modern standards on software development and project management. StarSim is a unique and self-contained platform: this feature allows to mitigate the risk of incompatibility, misunderstandings and loss of information that may arise using different software, simulation tools and facilities along the various phases. Modularity, flexibility, speed, connectivity, real time operation, fidelity with real world, ease of data management, effectiveness and congruence of the outputs with respect to the inputs are the sought-after features in the StarSim design. For every iteration of the methodology, StarSim guarantees the possibility to verify the behavior of the system under test thanks to the permanent availability of virtual models, that substitute all those elements not yet available and all the non-reproducible dynamics and environmental conditions. StarSim provides a furnished and user friendly database of models and interfaces that cover different levels of detail and fidelity, and supports the updating of the database allowing the user to create custom models (following few, simple rules). Progressively, pieces of the on board software and hardware can be introduced without stopping the process of design and verification, avoiding delays and loss of resources. StarSim has been used for the first time with the CubeSats belonging to the e-st@r program. It is an educational project carried out by students and researchers of the “CubeSat Team Polito” in which StarSim has been mainly used for the payload development, an Active Attitude Determination and Control System, but StarSim’s capabilities have also been updated to evaluate functionalities, operations and performances of the entire satellite. AIL, SIL, CIL, HIL simulations have been performed along all the phases of the project, successfully verifying a great number of functional and operational requirements. In particular, attitude determination algorithms, control laws, modes of operation have been selected and verified; software has been developed step by step and the bugs-free executable files have been loaded on the micro-controller. All the interfaces and protocols as well as data and commands handling have been verified. Actuators, logic and electrical circuits have been designed, built and tested and sensors calibration has been performed. Problems such as real time and synchronization have been solved and a complete hardware in the loop simulation test campaign both for A-ADCS standalone and for the entire satellite has been performed, verifying the satisfaction of a great number of CubeSat functional and operational requirements. The case study represents the first validation of the methodology with the first release of StarSim. It has been proven that the methodology is effective in demonstrating that improving the design and verification activities is a key point to increase the confidence level in the success of a space mission.