Industry 4.0 Technologies as an Obsolescence Mitigator for Testing of Mechatronic Systems in Aviation

Companies building products with a usage phase of 25 years and more, have suffered from obsolescence for decades. Software and hardware components inside of the supporting systems, such as avionics test benches, are particularly affected. They consist of components built for 3-7 years but expected to operate for decades. The lack of standardized, open and modular systems for special timing constraints increase the pressure and impede the interoperability in this field. Industry 4.0 systems offer exactly this, but do not support aviation standards. The research in this article aims to show that it is possible to use widespread Industry 4.0 standards and technology at the field level to achieve transferability and maintainability in the operation of test benches. This article describes an implemented and evaluated proof of concept of the implementation of an industrial ethernet standard EtherCAT for the ARINC 429 I/O for an aviation test bench. As a baseline, market available EtherCAT components were evaluated and selected. For the client development, standard components for the EtherCAT logic and ARINC 429 were used. Additionally, the full interoperability at the syntax level, was achieved by implementing a configuration approach of the I/O, in order to encode and decode the messages. The evaluation was performed using an Airbus A350-1000 test bench for secondary flight controls-namely the HighLift system.