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At Benchmark, we take pride in our innovative hardware-in-the-loop (HIL) testing process, a crucial step in ensuring that the propulsion systems we design for our mission partners meet the highest standards of performance, reliability, and safety. This testing approach is central to how we refine our technologies, making it a valuable asset for both our internal teams and our mission partners.
Benchmark’s Head of Research & Development, Jeff Gibson, and Rich Stelling, Lead GNC Engineer, provide an overview of what HIL testing entails and the benefits.
What is Hardware-in-the-Loop Testing?
Hardware-in-the-loop testing allows for real-time simulation of our propulsion systems by integrating actual hardware and software components into a virtual environment, allowing the system to control a simulated spacecraft using physics-based flight dynamics. Unlike pure simulation methods, HIL testing links hardware elements with software models, creating a dynamic testing scenario that simulates real-world mission conditions. This integration helps verify how the system will perform under the stresses and uncertainties of space operations, ensuring that it behaves exactly as expected during flight.
For our team at Benchmark, we institute this process early in the design phase, where we run thousands of Monte Carlo simulations to measure how our propulsion system performs at the mission level against variations in real-world parameters, such as mass properties, sensor noise, propulsion system dynamics, and environmental perturbations. As the design progresses and the spacecraft configuration matures, we’ll continue refining our models to increase fidelity and improve the accuracy of our predictions.
A Unique and Integrated Approach
What sets Benchmark’s HIL testing apart from other companies is our close coupling of propulsion expertise into the process. Unlike other integrators that have less visibility into real-world propulsion system performance, we use highly accurate, customized models derived directly from in-house tests on our thrusters, tanks, and other propulsion components. Data from every test is recorded, amassing an ongoing test data archive that allows us to gain unique insights into the performance and behavior of every assembly we build. Our ability to directly correlate test data to improve our modeling and simulation environment results in a higher degree of precision, and a faster development cycle that’s responsive to emerging challenges typical in spacecraft development programs.
This tight integration between propulsion engineering and guidance, navigation, and control (GNC) systems means that we can quickly adapt to changes or discover unexpected behaviors that might arise in the propulsion system during testing. By using the latest test data, we continuously improve the models, adjusting both hardware and software configurations to optimize performance and reliability. This approach maximizes maneuver performance, reduces risk, improves mission outcomes, and cuts down on costly last-minute changes.
Robust HIL testing also informs our SmartAIM™ offering to our mission partners. SmartAIM™ is our GNC software layer that abstracts maneuver commands and actively controls propulsion and other mobility subsystems. SmartAIM™ uses embedded sensors and adaptive controls to command thrusters and other effectors to execute maneuvers with more precision and efficiency than state-of-the-art systems. We’re currently using the HIL lab to perform integration testing between SmartAIM and our next generation flight avionics known as “MAAVRIC” to ensure the systems perform as expected and inform future development efforts.
The Value of Hardware-in-the-Loop Testing for Mission Partners
For our mission partners, Benchmark’s HIL testing is not just a technical exercise; it provides significant value by addressing potential mission risks before they arise. By running integrated simulations early and often, we create a robust digital twin that represents the spacecraft's behavior with impressive accuracy. This allows us to identify and correct potential issues before they occur in orbit.
As part of our Model Based Systems Engineering approach, our mission partners get targeted insight into the key metrics that matter most for their mission and gain confidence in the mobility system's ability to handle specific conditions. We run simulated maneuvers for orbit raising/lowering, phasing, collision avoidance, and other scenarios to demonstrate the end-to-end capabilities for our customers’ specific use cases. Additionally, these simulations provide immediate feedback on how hardware changes—such as tweaking thruster designs or modifying system configurations—will impact mission performance, allowing for quick and cost-effective adjustments during the development phase.
A Competitive Advantage
In an industry where precision and reliability are non-negotiable, Benchmark’s HIL testing stands out as a proven method for minimizing risk while optimizing mission outcomes. While other companies may skip this critical testing phase to save time and money, this often leads to costly program overruns or failures in flight. By contrast, our method ensures that we can deliver propulsion systems that are not only innovative but also capable of consistently performing dynamic operations in the challenging environment of space.
At Benchmark, we recognize that the success of our mission partners depends on the performance and reliability of our propulsion systems. Through our unique hardware-in-the-loop testing process, we provide the assurance that every system we deliver will meet or exceed performance expectations, delivering the mobility solutions needed for both commercial and defense missions. This makes Benchmark not only a supplier of propulsion systems but a trusted partner in the journey to success in space.
Additional Resources:
- Download the SmartAIM™ Data Sheet
- Read the Press Release: Benchmark Unveils First-Ever Autopilot for Satellites
- Read the SpaceNews article: Benchmark unveils driver assistance features for satellites