Integration Testing Station

HILS-based integration testing

The ITS is an integrated Hardware In the Loop Simulator (HILS) used for acceptance testing of sub-systems, verification purposes during integration and for system maintenance. The ITS extends traditional hardware in the loop simulation to provide fully automated verification of sub-systems such as FCUs, from automated text execution through to results verification and reporting. Available with DO-330 tool qualification evidence, the ITS is ideal for DO-178C developments where the time, effort and cost of verification process compliance can become enormous.

For clients, the ITS further supports on-site simulation, training, demonstration and maintenance on integrated aircraft. This high-fidelity, real-time dynamic simulator exercises the full functionality of FCUs, including injection of flight upset events and failure cases. The ITS is therefore ideal for system level training and demonstrations, with 3D visualisation on up to three external HD displays. Its built-in diagnostics suite also enables fast, on-site Remove & Replace (R&R) maintenance at both LRU and SRU levels. The ITS’ Ground Power Unit (GPU) powers the subsystems on-board aircraft during simulation and ensures that all simulations (especially long endurance simulations) remain uninterrupted by running the ITS from a built-in Uninterrupted Power Supply (UPS).



  • Integration Testing Station (ITS) for FCUs and other sub-systems
  • Test case definition, automated text execution & reporting
  • High-fidelity, real-time, dynamic simulation
  • 3D Visualisation, graphical reporting and logging tools
  • DO-330 Tool qualification for DO-178C developments
  • Flexible hardware and software architecture for customisation
  • Optional SRU level testing for maintenance support
  • On-board Ground Power Unit (GPU) for aircraft
  • On-board Uninterrupted Power Supply (UPS)

Advantages (using HILS-203R)

  • High-fidelity fixed and rotary wing aircraft dynamic models
  • Wind, atmospheric, magnetic field and gravity environment models
  • Complex ground-surface to landing gear interaction models
  • System specific sensor, actuator and propulsion models


  • On-site FCU and general sub-system integration, verification, training and maintenance tool
  • Custom FCU development, verification and integration tool (developer licenses available)
  • System verification, demonstration & flight test preparation tool
  • Flight and mission simulation for GCS verification (with payload simulation)

Technical Specifications

Aicraft Fixed-Wing, Rotary-Wing, Multi-Rotor
Landing Gear Tricycle and Tail Dragger, Helicopter Skids/Feet
Propulsion Piston, Electric, Turbine Engines with Propeller/Rotor, Jet Thrust
Drive Train Slip Clutch and One-Way Bearings
Fuel Fuel Tank and Fuel Flow
Inertia Mass and Centre of Mass, Moment of Inertia
Sensors GNSS (Rover/Base Station), IMU, Air-Data, Magnetometer, Radar Altimeter
Actuators Digital and Analog Servos
Subsystems Engine Control, Power Management, Custom Subsystems
Wind MIL-F-8785C
Atmospheric International Standard Atmosphere (ISA)
Magnetic WMM, MIL-W-89500
Gravitational WGS-84
Earth Geometry WGS-84
Operator Interface Embedded GUI, Direct or Wireless Remote Access
Visualization Up to 3x HD 3D Displays (External) with View Control
Monitoring Scope Traces, Text Boxes, Virtual Horizon Display
Test Cases / Scenarios Time & Event Based, Failures and Degradation, Environmental Conditions
Data Logging 1, 10 and 100 Hz Selectable, Rolling Data Log
Internal Simulation Rate 5 kHz
Simulation Time More than 24 Hours
Interfaces RS-422/485/232, Ethernet, GPIO, PWM, Input Capture, ADC/DAC, MIL-STD-1553, S/HDLC
Connectors Client Customized, Front/Rear, Optional Break-Out, Signal Board and SRU Testing
Dimensions Housed 43U 19” Rack
Power Supply 110/220 VAC, 50/60 Hz


Compact Port Break-out Connectors on Rear Panel
Extended Port Break-out Box for Comprehensive Simulations
xSIM Workbench Simulation Scenario Editor


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