Hardware In The Loop (HIL) System Development Platform

Problem:

At Skyways, I was tasked with designing and developing a hardware-in-the-loop (HIL) test platform for electromechanical UAV systems. The challenge was to create a system that minimized the risks of developing and testing features on production hardware while allowing future expandability. Tight timelines and budget constraints added complexity, especially in the need for custom wire harnesses due to the lack of a ready-made solution.

Action:

To address these challenges, I designed a modular, plug-and-play solution that streamlined new feature development and component integration across all aircraft subsystems. I developed custom wire harnesses for the HIL system, complete with detailed interconnect diagrams, and conducted a mass optimization and design analysis to ensure seamless integration with existing subsystems and future expandability.

Design Features:

  • T-slotted aluminum extrusion frame.
  • Pegboard panel for system reconfigurability.
  • Snap on component mounts for design modularity.
  • Custom built wire harnesses.
  • Custom junction PCBs for wire probing to
    assist in debugging.
  • Emergency stop switch and motor power switches.
  • Fully covered motor enclosures for operator safety.
  • GUI for testing subsystem performance

Results:

I completed the project within 8 weeks, delivering high-quality results that significantly reduced the time and cost needed to deploy new features. This solution enhanced Skyway's development process, enabling safer and more efficient testing on the HIL platform rather than on production hardware.

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