CTO Design process and digital twin optimisation

  1. High Integrity Systems
  2. CTO Design process and digital twin optimisation

Introduction

In the complex world of maritime platforms, traditional systems were often bogged down by outdated control and monitoring hardware. These older systems relied heavily on a sequential design process, which limited potential efficiencies and innovations. BAE Systems, recognising the need for a change, tasked High Integrity Systems (HIS) to take the reins and drive transformational change.

The Challenge

BAE Systems sought to improve their system’s efficiency and bring about a technological leap in their maritime business. The desired transformation aimed to incorporate advanced concepts such as digital twins, which have the potential to offer manifold benefits to users.

Solution & Implementation

HIS embarked on a comprehensive strategy:

  • High Integrity Model-Based Code Generation: The first step involved creating control and monitoring code for the operation of an actuator from a UAV programme. Leveraging a high-integrity model-based code generator ensured precision and reliability.
  • Real-time Physics Modelling: Physics models of the actuator, initially designed in Mathworks/Matlab, were transitioned into real-time models, ensuring their seamless integration into subsequent phases.
  • Virtual Rig Creation: By combining the control and monitoring code with the real-time actuator models, a ‘virtual rig’ was developed, offering a robust testing and development platform.
  • Integration on COTS Computing Platform: HIS then expertly integrated the control and monitoring software onto a Commercial Off-The-Shelf (COTS) computing platform. This was complemented with interfaces for the actuator and its sensors.
  • Digital Twin Development: The culmination of these efforts was the successful conversion of the real-time physics model into a digital twin of the actuator, bridging the digital and physical worlds.

Outcome

The demonstration led by HIS was a testament to the potential of modern engineering processes. Not only were development timelines slashed, but the project also showcased the possibility of performing multiple analysis activities concurrently. The ability to achieve higher software safety levels without escalating costs was another notable achievement. Furthermore, the successful integration of a digital twin with physical equipment heralded a new era for BAE Systems’ maritime operations.