An Investigation to Determine an Anomaly in Emulation of a Device
by
Kevin J. Silva
A Project Submitted to the Graduate
Faculty of Rensselaer Polytechnic Institute
in Partial Fulfillment of the
Requirements for the degree of
MASTER OF ENGINEERING
Major Subject: Mechanical Engineering
Approved:
_________________________________________
Ernesto Gutierrez-Miravete, Project Adviser
Rensselaer Polytechnic Institute
Hartford, CT
December, 2014
© Copyright 2014
by
Kevin J. Silva
All Rights Reserved
ii
CONTENTS
LIST OF TABLES ............................................................................................................ vi
LIST OF FIGURES ......................................................................................................... vii
LIST OF ACRONYMS .................................................................................................. viii
ACKNOWLEDGMENT .................................................................................................. ix
KEYWORDS ..................................................................................................................... x
ABSTRACT ..................................................................................................................... xi
1. Introduction.................................................................................................................. 1
1.1
Purpose ............................................................................................................... 1
1.2
Background ........................................................................................................ 1
1.3
Scope .................................................................................................................. 1
1.4
Problem Solving Methodology and Approach ................................................... 2
2. Introduction to Modeling and Simulation.................................................................... 4
2.1
Modeling and Simulation in System Development ........................................... 5
2.2
Modeling and Simulation in Test and Evaluation .............................................. 5
2.3
Modeling and Simulation in Training ................................................................ 6
3. Systems and Components ............................................................................................ 7
3.1
System One ........................................................................................................ 8
3.2
Interface system ................................................................................................. 8
3.3
Device ................................................................................................................ 8
3.4
Enclosure ............................................................................................................ 8
3.5
Wire Two ........................................................................................................... 8
3.6
Cables ................................................................................................................. 8
3.7
Connectors and Penetrators ................................................................................ 8
4. Software ..................................................................................................................... 10
5. Simulator One ............................................................................................................ 11
5.1
Simulator One Diagram ................................................................................... 11
iii
5.2
Simulator One Configurations ......................................................................... 13
5.3
Simulator One Summary .................................................................................. 14
6. Simulator Two ........................................................................................................... 15
6.1
Simulator Two Diagram ................................................................................... 15
6.2
Data Collection................................................................................................. 16
6.3
Functions .......................................................................................................... 16
6.4
Interfaces .......................................................................................................... 16
6.5
Simulator Two Summary ................................................................................. 17
7. Simulator Three ......................................................................................................... 18
7.1
Simulator Three Diagram................................................................................. 18
7.2
Data Collection................................................................................................. 19
7.3
Interfaces .......................................................................................................... 19
7.4
Simulator Three Summary ............................................................................... 19
8. Investigation .............................................................................................................. 20
8.1
Software Variations .......................................................................................... 20
8.2
Operator Error .................................................................................................. 20
8.3
Electrical Variations ......................................................................................... 20
8.4
Hardware .......................................................................................................... 29
8.5
Discussion ........................................................................................................ 29
8.6
Capabilities and Limitations of Simulators ...................................................... 35
9. Conclusion ................................................................................................................. 38
Appendix A – Interface Signals ....................................................................................... 39
System One to Device Signals ................................................................................... 39
Device to System One Signals ................................................................................... 40
Appendix B – Principles of Electrical Engineering ......................................................... 43
Fundamentals of Electronics...................................................................................... 43
Fundamentals of Circuitry ......................................................................................... 45
iv
Cabling ....................................................................................................................... 46
Signals........................................................................................................................ 46
Schematic Symbols .................................................................................................... 46
REFERENCES ................................................................................................................ 47
v
LIST OF TABLES
Table 1 – Firmware and Software IDs ............................................................................. 10
Table 2 – Simulator One Case Descriptions .................................................................... 13
Table 3 – Device Configuration Components ................................................................. 14
Table 4 – Cable Signal, Pin and Wire Gauge .................................................................. 22
Table 5 – Cables One, Two and Three Shielded Groups ................................................ 24
Table 6 – Cables One, Two and Three Grounding Pins .................................................. 24
Table 7 – Connector Four Signal, Pin and Wire Gauge .................................................. 26
Table 8 – Connector Four Wire Shielding Groups .......................................................... 28
Table 9 - Connector Four Grounding Pins ...................................................................... 29
Table 10 – Device and Simulator Hardware Configurations........................................... 29
Table 11 – Modified Cable Signal, Pin and Wire Gauge ................................................ 32
Table 12 – Connector Four, Cables One, Two and Three Wire Shielding Groups ......... 33
Table 13 - Connector Four, Cables One, Two and Three Grounding Pins ..................... 34
Table 14 – Comparison of Simulator Components to Baseline Configuration ............... 37
Table 15 – System One to the Device Signal Connector and Pin Identification ............. 40
Table 16 – Device to System One Signal Connector and Pin Identification ................... 42
Table 17 – Schematic Symbols7 ...................................................................................... 46
vi
LIST OF FIGURES
Figure 1 – Investigation Fishbone Diagram ...................................................................... 3
Figure 2 - Simulation Fidelity2 .......................................................................................... 4
Figure 3 – Interfacing Systems and Components .............................................................. 7
Figure 4 – Modified Interfacing Systems and Components .............................................. 9
Figure 5 – Simulator One Diagram ................................................................................. 11
Figure 6 – Simulator Two Configuration One ................................................................. 15
Figure 7 – Simulator Two Configuration Two ................................................................ 15
Figure 8 – Section 1 and Intermediate Schematic ........................................................... 18
Figure 9 – CPU Schematic .............................................................................................. 18
Figure 10 – Cables One, Two and Three Wiring Schematic ........................................... 23
Figure 11 – Connector Four Wiring Schematic ............................................................... 27
Figure 12 – Summarized Potential Causes Fishbone Diagram ....................................... 30
Figure 13 – Direct Current6 ............................................................................................. 44
Figure 14 – Alternating Current6 ..................................................................................... 44
Figure 15 – Delta and WYE Configurations5 .................................................................. 45
Figure 16 – Capacitor Construction6 ............................................................................... 45
vii
LIST OF ACRONYMS
Acronym
Definition
AC
Alternating Current
ACC
Alternating Current Complement
ASWTT
Anti-Submarine Warfare Team Trainer
CB
Control Box
Comp 1
Component 1
Comp 2
Component 2
Comp 3
Component 3
DC
Direct Current
CPU
Central Processing Unit
PS
Power Supply
M&S
Modeling and Simulation
TRL
Technology Readiness Level
SIL/HWIL
Software/Hardware-in-the-Loop
USN
United States Navy
VAC
Volts Alternating Current
viii
ACKNOWLEDGMENT
I would like to thank my family and girlfriend Katie for being supportive during the long
hours needed to complete my coursework and this project to earn my Master’s degree. I
would also like to thank David Abdow who mentored me and Robert Leduc in helping
select a topic where I gained valuable knowledge in my career. Thank you to the
individuals who provided guidance and took time to answer my questions that I came
across while writing the report including David Reynolds, Edmund Costa and Daniel
Masse.
ix
KEYWORDS

Simulator

Emulation

Software-in-Loop

Hardware-in-Loop

Simulator Fidelity

Problem Solving Method

Root Cause Analysis

System Development

Test and Evaluation

Training
x
ABSTRACT
This report is an investigation to determine an anomaly in emulation of a device. The
problem is that there was an occurrence where simulators did not properly emulate a
device. The analysis to investigate and resolve the issue used a military problem solving
process. Facts on baseline configurations and the three simulators, which included
simulator one, simulator two and simulator three were gathered and assumptions were
made. A criterion to evaluate the possible causes was based off the facts and
assumptions that were obtained. A fishbone diagram was used to organize the potential
causes of the problem from the gathered information and a solution was attained by
process of elimination. It was concluded that connector four affected the performance of
the simulators and that the simulators operated as expected when connector four was
absent.
xi
1. Introduction
The United States Navy (USN) implements a test and evaluation program to provide
engineers and decision-makers with knowledge to verify and validate that systems
operate appropriately, to assist in managing risk, to measure technical progress, and to
characterize operational effectiveness, suitability, and survivability. There is a variety of
equipment including simulators that are temporarily installed to verify and validate
modernized or new systems. Simulators are designed to interface with systems, similar
to a device, to test and evaluate the systems without using an actual device. Testing with
an actual device may not be feasible due to multiple factors such as cost, availability and
safety. In addition, advantages to using a simulator include: 1) Testing of abnormal
device conditions to verify that the systems are capable of identifying device faults and
2) Simulators are portable.
1.1 Purpose
The purpose of this report was to investigate why certain selected simulators did not
properly emulate the device configurations. Differences between simulator one,
simulator two and simulator three with an actual device were identified. The device will
be considered the baseline and differences with simulators will be measured from the
baseline.
1.2 Background
Simulators are designed to emulate the latest device. However, there has been an
occurrence whereby simulators did not properly emulate the device.
1.3 Scope
The objective of the work was to identify why the simulators did not properly emulate
device configurations. In addition, alternate outcomes of the report that may be
beneficial include outlining the limitations of each type of simulator such that the best fit
simulator will be used for system development, test and evaluation or training.
1
1.4 Problem Solving Methodology and Approach
The analysis to investigate and resolve this issue will use the following military problem
solving process1:
1) Recognize and define the problem
Defining the problem will be the first step in the investigation. The description of
the problem will include both scope and its limitations.
2) Gather facts and make assumptions
This step will include gathering the information needed to determine a solution.
Facts will be verifiable pieces of information, and assumptions will be
information that can be accepted as true, but cannot be readily verified.
3) Define end state and establish criteria
Criterion which will be set as the standard will be developed to evaluate the
information gathered.
4) Develop possible solutions
Use gathered information and criteria to brainstorm and develop possible
solutions.
5) Analyze and compare solutions
Each possible solution will be analyzed and compared. The first step to this
process will be to evaluate each solution for its merits and shortcomings using
the criteria that was developed. Then each solution will be compared to one
another.
6) Select and implement solution
Select the best solution based on the analysis in step 5 of the evaluating criteria.
7) Analyze solution for effectiveness
Analyze solution to determine if the defined problem is resolved.
The problem and scope are defined in section 1.1 and 1.3 respectively. There are
potentially multiple root causes of why the simulators did not emulate the device. Facts
and assumptions were gathered in four areas where the cause of the problem could lie.
These areas included software variations, electrical variations, operator error and
2
hardware. The criterion to evaluate the possible causes will be based off the facts and
assumptions that are obtained.
A fishbone diagram will be used to organize the potential causes in order to streamline
the development and comparison of the solutions process. A fishbone diagram is a tool
that is used in root cause analysis to visually represent the potential causes and the effect
of a problem. The “bones” of the fish are designated as the causes and the “head” of the
fish is the effect or the problem. Figure 1 shows the fishbone diagram that will be used
in this investigation.
Figure 1 – Investigation Fishbone Diagram
The potential causes of why the simulators did not properly operate in the areas of
software variations, electrical variations, operator error and hardware will be identified.
Process of elimination will then be used to determine the most likely cause and solution.
Lastly, troubleshooting the problem will determine if the solution is effective.
3
2. Introduction to Modeling and Simulation
Modeling and Simulation (M&S) provides a basis for making technical and
programmatic decisions early in concept studies through test, evaluation and training on
a system. The system development process requires engineers and scientists to construct
data driven decisions. Obtaining the data by testing the actual system may not be
feasible. The fidelity of the data that is provided by the M&S is dependent on the
maturity of the simulation.
Early in a systems development, simulations are fairly simple and fidelity typically
grows as the system matures. The simulation fidelity can and must increase as system
development progresses. Figure 2 illustrates the range of simulation fidelities based on
maturity or technology readiness level (TRL). Lower fidelity analytical tools are
generally preferred for initial system conceptual or architectural studies because they
permit a broad range of alternatives to be studied relatively quickly and because the
system parameters are not yet known to a precision that would justify a higher-fidelity
simulation. As the system design matures, higher fidelity digital simulations replace
analytical tools and more generic simulations to support algorithm development and
detailed performance predictions. The digital simulations are eventually supplemented
by software/hardware-in-the-loop (SIL/HWIL) simulations. SIL/HWIL uses actual
system software and components to develop the most realistic simulation of the system2.
Figure 2 - Simulation Fidelity2
4
M&S allows the analysis of a system’s capabilities, capacities, and behaviors without
requiring the construction or experimentation with the actual system and supports an
actual system from development, test and evaluation and training.
2.1 Modeling and Simulation in System Development
Use of M&S during system development provides greater control over development,
provides a superior design, reduces risk and reduces development costs. Traditional
system development approaches follow similar steps: 3
1) Define requirements contained in a requirements document.
2) A design specification is created to provide complete documentation of all
aspects of system design. As the design specification becomes more detailed, the
design of each subsystem begins to impose interface requirements that are fed
back to the requirements document.
3) Prototyping and integration.
Prior to M&S in system development, the design and production of a system was an
iterative process that included designing, building, testing and redesigning. This method
proved to be slow and costly. M&S provides a method to mathematically model a
subsystem and iterate the mathematical model to produce a design. Although the design
is represented by a model, this method results in a better design and enables a reduction
in the number of prototypes required to reach the final product.
2.2 Modeling and Simulation in Test and Evaluation
M&S can be used to evaluate a system interface design and operation. As systems
become complex there are interfaces that a system may have with another system. The
interface between the two systems must be tested to verify correct design and operation
of the systems in unison. It may not be preferred to test the interface between two actual
systems due to factors such as, 1) Risk of damaging a system and/or 2) The systems may
not be located in the same facility. A simulation can be developed that operationally
5
represents the interfacing system such that interfaces may be tested prior to the actual
systems being coupled for the first time.
2.3 Modeling and Simulation in Training
It may not be feasible or preferred to train on functioning systems due to factors such as
cost, safety and risk of damaging the system. The armed forces are a prime example of
using M&S to train personnel on the use of systems and developments of battlespace
scenarios. SINDEL has developed a tactical Anti-Submarine Warfare Team Trainer
(ASWTT) where sailors have the opportunity to train in tactical scenarios4. ASWTT has
the capability to:

Generate and simulate complex tactic scenarios to include models of different
military platforms.

Provide operator interface with actual equipment.

Simulate weapons, countermeasures, underwater acoustics and sensors.
M&S programs such as ASWTT allow the armed forces to train for battlespace tactics
and awareness without the significant costs and reducing the availability of actual
platforms. In addition, use of M&S system trainers allows for training of abnormal
system operation. M&S can be used as a tool to train operators for system malfunctions
or casualties that may occur during actual system operation.
6
3. Systems and Components
There are systems and components that support the interface signal transfer between
system one and the device. Figure 3 shows the major systems and components that
support the interface.
Figure 3 – Interfacing Systems and Components
All signals are originated from either system one or the device. The device has the
capability to be in two states. State one signals are transferred through the interface
system and cables one, two and three with the exception of a test of communications
over wire one and two prior to state two. State two signals are transferred through wire
one and wire two to the device’s CPU. This section will provide a description of the
interfacing systems and components shown in Figure 3.
7
3.1 System One
System one provides automatic and computer-assisted, manually interactive device
setting selection, state one control, state one monitoring, state two control, and state two
device monitoring.
3.2 Interface system
The interface system provides an interface between system one and the device.
3.3 Device
The device receives stores and data from system one via cables one, two and three
and/or wires one and two. In addition, the device also provides status information to
system one via cables one, two and three and/or wires one and two.
3.4 Enclosure
The enclosure houses and protects the device.
3.5 Wire Two
Wire two is a coil of wire that is located inside the enclosure with the device. One end of
the wire is connected to connector three and the other is connected to the penetrator.
Wire one and two are the communication path to the device with system one during state
two.
3.6 Cables
Cables one, two and three provide the communication path between the device, interface
system and system one. Cables two and three connect the interface system to the outside
side of connector one and are assumed to have the same wiring configurations. Cable
one connects the inside of connector one to connector two.
3.7 Connectors and Penetrators
Four connectors and one penetrator are shown in Figure 3. The in line connector
connects cable two and three together and connector one connects cables one and two
8
through the enclosure. Cable one connects connector one with connector two on the
device. Lastly, wire two connects connector three to the penetrator. The penetrator
provides a path for wire one through the enclosure. It will be assumed that the in line
connector, connector one, penetrator, connector two and connector three do not alter the
signals that are transferred between system one, the interface system and the device.
Connector four is not normally installed and is placed in line between cable two and
connector one for data collection during testing. Figure 4 shows the interfacing systems
and components configuration with connector four.
Figure 4 – Modified Interfacing Systems and Components
9
4. Software
There are three different configurations of the device and there are multiple firmware
and software IDs that could be installed dependent on the configuration. Table 1
identifies the firmware and software IDs for each configuration.
Table 1 – Firmware and Software IDs
Firmware ID Software ID
1
11
Configuration
2
10
One
3
9
4
8
Configuration
5
7
Two
6
6
7
5
8
4
Configuration
9
3
Three
10
2
11
1
10
5. Simulator One
Simulator one is an electronic test simulator which replicates the device during state one,
and state two phases of operation. Simulator one contains the actual device computer
electronics and is capable of simulating other portions of the device. Simulator one is
used to conduct state one and state two interface testing.
5.1 Simulator One Diagram
The diagram of simulator one is shown in Figure 5. Simulator one can be broken down
into three sections; first is data collection, second is the interface unit and lastly, actual
computer (CPU) hardware.
Figure 5 – Simulator One Diagram
5.1.1
Data Collection
Data collection is comprised of the interface test set, Dolch CPU and a printer. The
interface test set is the operators interface with simulator one and displays the data being
11
transmitted from system one to the simulator. Data that is transferred via cables one, two
and three is obtained from installing connector four between system one and the
simulator then connecting the interface test set to J3 on connector four. Data that is
transferred over wire one is obtained from splitting the wire using a BNC tee. These
connections are for data extraction and do not manipulate the data transfer between
system one and the simulator.
5.1.2
Interface Unit
The interface unit houses the electronics that simulate the electrical portion of the
devices Component One (Comp 1) and Component Two (Comp 2) to support the Central
Processing Unit (CPU) functions. It also provides power to the Power Supply (PS) and
Control Box (CB) during self-test and state two. The interface unit allows the user to
change the identification bits and also override a device shutdown.
During state one testing, the interface unit serves as the interface between system one
and the CPU hardware. The CPU hardware is powered by the system one interface over
cables one, two and three and does not require Comp 1 and Comp 2 simulation. All the
interface signals can be sent to the CPU hardware over cables one, two and three and
wire one.
The interface unit provides the capability of state two testing to simulator one. During
state one the CPU hardware is powered by system one over cables one, two and three. In
state two the device is no longer connected to system one via cables one, two and three
and is assumed to be producing its own power. Therefore, the power to the CPU
hardware from system one is dropped when the device is in state two and power is
supplied from the two power supplies in the interface unit.
5.1.3
CPU Hardware
The CPU hardware section contains three components, the PS, Component 3 (Comp 3)
and the CB. The PS receives 275 VDC from the interface unit and supplies 5 VDC, +/19 VDC and 28 VDC to the CB. Comp 3 is the interface for wire one signals that are
12
sent between the CB and system one. The CB communicates with system one and
controls the various functions of the device. The CB houses actual device circuit cards
used in the CPU of the device. Simulator one is capable of emulating all configurations
and firmware/software versions of the device by modifying configurations of CPU
hardware.
5.1.4 Delta WYE Transformer
The delta WYE transformer receives 120 VAC 3 phase delta from simulator two and
converts it to 208 VAC 3 phase WYE power. This WYE power is then supplied to the
interface unit through connector J3 and is used during a self-test and state two.
5.2 Simulator One Configurations
Simulator one can be configured multiple ways to emulate the device configurations one,
two and three. All simulator one configurations include the interface unit, cabling, BNC
“T”, delta WYE transformer and a heat exchanger. Other components are added to allow
for the different configurations. Table 2 lists the six cases that make up simulator one
and a description of the components included in the case. Table 3 lists the cases that are
required to make up a certain configuration of the device. A “Y” indicates a yes and that
it is included, and a “N” indicates a no and it is not included.
Table 2 – Simulator One Case Descriptions
Case
1
2
3
4
5
6
Description of Components
A) Interface Unit
B) Cabling
C) BNC "T"
A) Delta WYE Transformer
A) Control Box
B) Cabling
C) Shorting Plug
A) Power Supply
B) Cabling
C) Comp 3
A) Configurations 2 & 3 Control Box
B) Shorting Plug
C) Comp 3
A) Heat Exchanger
13
Table 3 – Device Configuration Components
Case
1
2
3
4
5
6
Configuration 1 Configuration 2 Configuration 3
Y
Y
Y
Y
Y
Y
Y
N
N
Y
N
N
N
Y
Y
Y
Y
Y
5.3 Simulator One Summary
Simulator one uses SIL/HWIL to build the overall emulator. Comp 1 and Comp 2 are
programmed into circuit cards that are designed to emulate the actual components in the
device. Advantages of simulating these components are that it allows for both state one
and state two testing. However, these circuit cards cannot perfectly emulate the actual
components.
The CPU hardware section is actual device HWIL. The CB houses actual device circuit
cards used in the CPU and this section can be modified to simulate all configurations and
firmware/software versions of the device. Although this section is made up of actual
hardware, it does have differences. All internal cabling and connectors for the hardware
and cable one are modified from actual device components. The interface unit handles
signals transferred over cables one, two and three and wire one and lastly, there is no
wire two. These differences, in addition with substituted actual components limit
simulator one’s ability of emulating the device by changing its electrical characteristics
including power loads, grounding, resistance/impedance, inductance and capacitance.
This provides a medium fidelity test of system one to device interface with respect to
Figure 2.
14
6. Simulator Two
Simulator two uses software and functions to emulate all components of the device.
Simulator two is installed in an actual use environment and simulates state one and state
two characteristics for all device configurations.
6.1 Simulator Two Diagram
There are two simulator two configurations that could be installed. Figure 6 shows the
first configuration. In this configuration, simulator two is connected to connector one
which is connected to the interface system. Figure 7 shows the second configuration. In
this configuration, simulator two is connected to the interface system via connection
panels and the interface system is connected to the enclosure.
Figure 6 – Simulator Two Configuration One
Figure 7 – Simulator Two Configuration Two
15
6.2 Data Collection
Simulator two is capable of performance monitoring and fault localization of circuits and
functions that can be detected by system one. In addition, simulator two displays all
voltages received from system one to simulator two for troubleshooting and can
determine that all internal power supply voltages are within tolerance. If detailed data is
needed, the interface test set, Dolch CPU and a printer that is used with the simulator
one can be integrated by installing connector four.
6.3
Functions
The following paragraphs provide a brief description of the simulator two functions that
emulate the device.
6.3.1
Digital Input/Output Functions
Simulator two monitors and decodes data that is sent over wire one and generates output
signals for device emulations. These functions are done during both state one and state
two.
6.3.2
Discrete Input/Output Functions
The discrete input/output function processes discrete signals between system one and
simulator two. Power received from system one is routed back as device monitor and
status signals.
6.3.3
Cable Interface Function
The cable interface function provides conversion of power and command signals
received from system one.
6.4 Interfaces
Simulator two interfaces with either the interface system directly or through a
connection panel depending on the configuration and is powered by a 120VAC, 60 Hz
single phase external source.
16
6.5 Simulator Two Summary
Simulator two is an emulator that uses software and the functions described above to
emulate the device components and software. Simulator two is capable of performing
system troubleshooting using tools that are programmed into the emulator. It can also be
used in conjunction with a connector four and interface test set computer for additional
troubleshooting capability. However, the extent of troubleshooting is limited because
simulator two does not include actual device components. All components of the device
are emulated and cabling/connectors differ which alter electrical characteristics and
provide a low fidelity test of system one to device interface with respect to Figure 2. An
advantage of the simulator two is that it is installed in an actual use environment and it
can easily be used for training of personnel.
17
7. Simulator Three
Simulator three is the latest simulator that best replicates the device during the state one
phase of operation. Simulator three contains actual device CPU electronics, Comp 1 and
Comp 2. Simulator three also integrates device cabling and connectors. Using actual
components provides a more realistic emulation of the device. Simulator three is also
capable of simulating all firmware/software versions of the device by modifying
configurations of the CPU hardware.
7.1 Simulator Three Diagram
Figure 8 shows section one and intermediate schematic. Figure 9 shows the CPU
schematic.
Figure 8 – Section 1 and Intermediate Schematic
Figure 9 – CPU Schematic
18
Simulator three components can be broken into three sections that include section one,
intermediate and CPU. Device configurations one, two and three use the same section
one and intermediate components and configuration one differs from configurations two
and three in the CPU section.
7.2 Data Collection
Simulator three can integrate the interface test set, Dolch CPU and a printer that is used
with simulator one by installing connector four.
7.3 Interfaces
Simulator three interfaces with system one using an actual cable one. Cable one connects
to the inside of connector one and connector two. Connector two splits the power and
data signals. Power is sent to the regulator and then to the CPU section. The data signals
are sent directly to the CPU section. In addition, system one transfers state two data
through wire one and two before being processed by the CPU section.
7.4 Simulator Three Summary
Simulator three provides a high fidelity test of device to system one interface with
respect to Figure 2. The limitation of simulator three is that it cannot be used for state
two testing. Simulator three uses actual device components and there are no emulators
for the simulator to enter into state two. Emulators for Comp 1 and Comp 2 of the device
must be added to simulator three for state two testing capability.
19
8. Investigation
Information was gathered in regards to the systems and components, software, simulator
one, two and three in the previous sections of the report. This section will use the
gathered information to investigate the areas of software variations, operator error,
electrical variations and hardware where the possible causes of the problem may exist.
Appendix A and Appendix B provide a background to the interface signals and
principles to electrical engineering respectively that are discussed in this section for
reference.
8.1 Software Variations
All three simulators have the capability to download and run all device firmware and
software variants. There is no variation in firmware and software between the simulators
and the device.
8.2 Operator Error
There is a possibility that the operator installed and/or used the simulators improperly.
This could be caused by a limited amount of training in the use of the equipment.
Simulator two is permanently installed in an actual use environment; however, multiple
cables need to be connected to components for the installation of the simulator one and
three. In addition to properly installing the equipment, the simulators must be operated
correctly to properly emulate the device.
8.3 Electrical Variations
8.3.1
Cabling
8.3.1.1 Internal Cabling
Simulator three interfaces all internal components with actual device internal cabling.
Both simulator one and two uses modified internal cabling.
20
8.3.1.2 External Cabling
Cables one, two and three are the external cables that interface the device, interface
system and system one. The interfacing signals and power to the device are transferred
through individual wires within the cables. Table 4 identifies the signal associated with
each pin in the cable connectors and the gauge of wire in the cable. Figure 10 shows the
wiring schematic from the interface system to the device.
21
Table 4 – Cable Signal, Pin and Wire Gauge
Signal
Data Shield Carry Through
Sync I
Identification Bit 2
Start AC
Device Monitor
Open Circuit
Enclosure Return
Data Ground Reference
Device Downloader 2
Start ACC
DC Operational Power Return
Data Enable
Data Enable Complement
Data - Device to System One Complement
Data - Device to System One
Data - System One to Device
Data - System One to Device Complement
Data Clock
Data Clock Complement
Probe Short I
Open Circuit
Wire Return
Identification Bit 0
Identification Bit 1
Identification Power
Energize Order AC
Open Circuit
Open Circuit
Sync 2
Sync 3
Open Circuit
Identification Bit 4
Open Circuit
Cable One Sense
Open Circuit
Open Circuit
Cable One Sense Return
Device Downloader I
DC Operational Power
Range Sync Common
Probe Short 2
Sync Clock Stop/Recorder Start
Open Circuit
Identification Bit 3
Range Clock Start/Clock Sync
Open Circuit
Identification Bit 5
Simulator Present
Device Ground
Open Circuit
Energize Order ACC
AC Operational Power, Phase A
AC Operational Power, Phase C
AC Operational Power, Phase N
AC Operational Power, Phase B
Open Circuit
22
Cable Two
Pin and Three
AWG
A
L
22
V
22
W
18
M
22
N
16
X
18
Y
20
P
22
Z
18
R
12
H
20
S
20
Z
20
R
20
P
20
Y
20
X
20
N
20
M
22
W
18
V
22
C
22
L
22
U
22
T
18
K
22
E
12
F
22
D
22
B
18
G
22
AC
16
H
22
J
18
S
18
A
14
J
14
T
12
AA
16
AG
22
AF
22
AE
16
AK
22
AJ
22
AD
22
AH
22
AB
22
U
22
K
16
B
18
F
12
E
12
D
12
G
12
C
N/A
Cable
One
22
22
22
22
N/A
22
22
22
22
22
22
22
22
22
22
22
22
22
N/A
22
22
N/A
22
22
N/A
N/A
22
22
N/A
22
N/A
22
N/A
N/A
22
22
22
22
22
22
N/A
22
22
N/A
N/A
N/A
22
N/A
22
20
20
N/A
20
N/A
Figure 10 – Cables One, Two and Three Wiring Schematic
23
There are leads from cable two and three that are not connected to cable one and are left
as an open circuit. The circled pin connections in Figure 10 specify shielded wires. Table
5 identifies the interfacing signal functions that are shielded in groups internal to cables
one, two and three. The shield group name is on the left column and the signals that are
shielded together are in the same row. For example, in the data shield group, data enable
and data enable complement are shielded together in cables one, two and three.
Table 5 – Cables One, Two and Three Shielded Groups
Data Enable
Data Enable Complement
Data Enable
Data Enable Complement
Data Device to System One
Data Device to System One Complement
Data Device to System One
Data Device to System One Complement
Data System One to Device
Data System One to Device Complement
Data System One to Device
Data System One to Device Complement
Data Clock
Data Clock Complement
Data Clock
Data Clock Complement
AC Operational
Power Phase, C
AC Operational
Power Phase, A
AC Operational
Power Phase, A
AC Operational
Power Phase, B
AC Operational Power Phase,
N
DC Operational Power Return
Enclosure Return
Energize Order AC
Connector One
Data Shield
AC Power
Shield
Enclosure
Wire Return,
Return, Energize
Probe Short I & Device Monitor
DC Power
Order & "N"
"W" Open Circuit & Start Shield
Shield
Open Circuit
Shield
Shield
Sync I &
Sync 2
Shield
Open
Circuit
Shield
Cable One
Signal
Energize Order ACC
AC Operational
Power Phase, B
AC Operational Power Phase, C
DC Operational Power
DC Operational Power Return
Enclosure Return
Energize Order ACC
Energize Order AC
Device Monitor
Connector Two
Cable Two and Three
Signal
Shield Group
Device Monitor
Start AC
Start AC
Start ACC
Start ACC
Wire Return
Wire Return
Sync I
Sync 2
Open Circuit "K"
Open Circuit "E"
The shield groups are connected to one another and grounded to certain pins in the
cables. The grounding pins for each cable are identified in Table 6.
Table 6 – Cables One, Two and Three Grounding Pins
Cable/Connector
Shield Grounding Pin(s)
Cable One
A&Y
Cable Two and Three
A
Notes
Pin A - Data Shield Carry Through
Pin Y - Data Ground Reference
None
All three simulators incorporate cables two and three with the exception of simulator two
configuration two. Simulator three uses an actual cable one where simulator one and two
use a modified cable one.
24
8.3.2 Connectors and Penetrators
The line connector, connector one, connector two, connector three and penetrator are pin
and socket type connectors. These pin and socket connectors do not use internal wiring
to connect the leads from each end of the cable or wire. Therefore, it will be assumed
that these connectors do not significantly alter the signals that are transferred between
system one, interface system and the device. In addition, these connectors are normally
installed in the baseline configuration.
Connector four is not normally installed and is placed in line between cable two and
connector one during testing. Connector four is a pin and socket type connector with
internal wiring that connects the leads from each end of the cable or wire. There are 5
connections on connector four named E-1, E-2, J-1, J-2, and J-3. Connection J-3 is used
for data extraction and does not alter signals between system one and the device.
Connections E-1 (connector one connection), E-2 (cable two connection) and J-1 (test
connection) will be discussed.
When connector four is installed the interface between system one, interface system and
the device should operate as the system would without connector four installed. Internal
to connector four, the signals are transferred in wires that connect the E-1 and E-2
connections. Voltages and frequencies between system one, interface system and the
device can be measured by using the J-1 connection. Table 7 shows the signal, pin and
wire gauge of each wire internal to connector four. The row across the top of the table
identifies the wire gauges that connect E-1/E-2 to J-1 and the numbers that run
diagonally are the gauges of the wires that connect E-1 to E-2. Figure 11 shows the
wiring schematic of connector four. As you can see, each specific pin is connected
together internally. For example, pin A on E-1 is connected to pin A on E-2 and pin A
on J-1. Table 8 shows the wire shielding configuration within connector four and lastly,
Table 9 shows the connector four wire shield grounding configuration.
25
Table 7 – Connector Four Signal, Pin and Wire Gauge
Signal
Data Shield Carry Through
Sync I
Identification Bit 2
Start AC
Device Monitor
Open Circuit
Enclosure Return
Data Ground Reference
Device Downloader 2
Start ACC
DC Operational Power Return
Data Enable
Data Enable Complement
Data - Device to System One Complement
Data - Device to System One
Data - System One to Device
Data - System One to Device Complement
Data Clock
Data Clock Complement
Probe Short I
Open Circuit
Wire Return
Identification Bit 0
Identification Bit 1
identification Power
Energize Order AC
Open Circuit
Open Circuit
Sync 2
Sync 3
Open Circuit
Identification Bit 4
Open Circuit
Cable One Sense
Open Circuit
Open Circuit
Cable One Sense Return
Device Downloader I
DC Operational Power
Range Sync Common
Probe Short 2
Sync Clock Stop/Recorder Start
Open Circuit
Identification Bit 3
Range Clock Start/Clock Sync
Open Circuit
Identification Bit 5
Simulator Present
Device Ground
Open Circuit
Energize Order ACC
AC Operational Power, Phase A
AC Operational Power, Phase C
AC Operational Power, Phase N
AC Operational Power, Phase B
Open Circuit
Connector Four
A L V W M N X Y P Z R H S Z R P Y X N M W V C L U T K E F D B G AC H J
S A J
T AA AG AF AE AK AJ AD AH AB U K B F E D G C
20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 12 12 12 12 20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
12
12
12
12
20
26
Figure 11 – Connector Four Wiring Schematic
27
Table 8 – Connector Four Wire Shielding Groups
Connector Four
Signal
Data Shield
Shield Group
Data Enable Complement
Data Device to System One
Data Device to System One Complement
Data System One to Device
Data System One to Device Complement
AC Power
Shield
Data Clock
Data Clock Complement
AC Operational Power, Phase A
AC Operational Power, Phase B
AC Operational Power, Phase, C
AC Operational Power, Phase N
Enclosure
Return, Energize
DC Power
Order & "N"
Shield
Open Circuit
Shield
DC Operational Power Return
Enclosure Return
Device Monitor
Start AC
Start ACC
Identification Power
Identification Bit 0
Identification Bit 1
Probe Short I
"W" Open Circuit
Identification Bit 2
Data Ground Reference
Device Downloader 2
Wire Return
Sync I
Open Circuit "AC"
Open Circuit "AE"
28
Connector Four Output (E-1)
"N" Open Circuit
Connector Four Input (E-2)
Identification Device Monitor
Shield
& Start Shield
Data Ground
Reference &
Device
Downloader 2
Shield
Wire Return,
Probe Short I &
"W" Open Circuit
Shield
Sync I &
Sync 2
Shield
Open
Circuit
Shield
Data Enable
Table 9 - Connector Four Grounding Pins
Cable/Connector
Connector
Four
Shield Grounding Pin(s)
E-1 to E-2 A
J1
No Grounding
Notes
E1 and E2 are the connections to
connector one and cable two
respectively. J1 is a connection for test
equipment.
Both simulator one and three require that connector four be installed for data collection.
Simulator two is capable of limited data collection without connector four however, if
detailed data is needed simulator three also requires that connector four be installed.
8.4 Hardware
Table 10 shows the differences in hardware between the device and each simulator.
Simulator three uses actual hardware from the device. Simulator one uses a combination
of actual and simulated hardware with no wire two. Simulator two uses no device
hardware and does not include wire two.
Table 10 – Device and Simulator Hardware Configurations
Device
Wire Two Regulator
CB
Comp 3
Actual
Actual
Comp 1
Comp 2
Simulator One
None
Simulated
Simulator Two
None
Simulated Simulated Simulated Simulated Simulated
Simulator Three
Actual
Actual
Actual
Actual
Simulated Simulated
Actual
Actual
8.5 Discussion
Software variations, electrical variations, operator error and hardware were investigated
to find potential causes of why the simulator did not properly emulate the device. The
summarized potential causes are identified in the fishbone diagram shown in Figure 12.
29
Figure 12 – Summarized Potential Causes Fishbone Diagram
There are multiple firmware and software versions of the device. The three simulators
are capable of running all software configurations. There is no variation between the
simulators and the device in regards to firmware and software. Therefore, it is not likely
that the firmware and software caused the simulator to not properly emulate the device.
The operator could have installed and/or operated the simulators incorrectly. Simulator
two is permanently installed in an actual use environment and previously tested which
negates the possibility of installation error by the operator. Simulator one and three
require installation by the operator before use. All three simulators have the possibility
that an operator used them improperly. The possible cause of operator installation and
operation was eliminated when it was discovered that the operators are experienced and
followed a standard operating procedure in the installation and use of the simulators.
Also, an additional operator reviewed the installation and operation of the simulators.
Seven hardware components were considered to be potential causes of the problem. As
shown in Table 10, there are multiple combinations of hardware amoung the three
30
simulators. All three simulators did not properly emulate the device. Between the
different hardware combinations it can be assumed that the likelihood of all hardware
configurations failing in a similar manner is low. Therefore, it was determined that the
hardware is not likely to cause the simulator to improperly emulate the device.
The last possible causes of the problem are cabling and connector four. To further
investigate electrical variations, the wire gauge and shield information that was
previously gathered on the cables and connector four was combined and is shown in
Table 11 and Table 12 respectively.
31
Table 11 – Modified Cable Signal, Pin and Wire Gauge
Signal
Cable Two
and Three
Pin
Data Shield Carry Through
Sync I
Identification Bit 2
Start AC
Device Monitor
Open Circuit
Enclosure Return
Data Ground Reference
Device Downloader 2
Start ACC
DC Operational Power Return
Data Enable
Data Enable Complement
Data - Device to System One Complement
Data - Device to System One
Data - System One to Device
Data - System One to Device Complement
Data Clock
Data Clock Complement
Probe Short I
Open Circuit
Wire Return
Identification Bit 0
Identification Bit 1
Identification Power
Energize Order AC
Open Circuit
Open Circuit
Sync 2
Sync 3
Open Circuit
Identification Bit 4
Open Circuit
Cable One Sense
Open Circuit
Open Circuit
Cable One Sense Return
Device Downloader I
DC Operational Power
Range Sync Common
Probe Short 2
Sync Clock Stop/Recorder Start
Open Circuit
Identification Bit 3
Range Clock Start/Clock Sync
Open Circuit
Identification Bit 5
Simulator Present
Device Ground
Open Circuit
Energize Order ACC
AC Operational Power, Phase A
AC Operational Power, Phase C
AC Operational Power, Phase N
AC Operational Power, Phase B
Open Circuit
A
L
V
W
M
N
X
Y
P
Z
R
H
S
Z
R
P
Y
X
N
M
W
V
C
L
U
T
K
E
F
D
B
G
AC
H
J
S
A
J
T
AA
AG
AF
AE
AK
AJ
AD
AH
AB
U
K
B
F
E
D
G
C
Connector Four
A L V W M N X Y P Z R H S Z R P Y X N M W V C L U T K E F D B G AC H J
S A J
T AA AG AF AE AK AJ AD AH AB U K B F E D G C
AWG 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 12 12 12 12 20
20
22
20
22
20
18
20
22
20
16
20
18
20
20
20
22
20
18
20
12
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
22
20
18
20
22
20
22
20
22
20
22
20
18
20
22
20
12
20
22
20
22
20
18
20
22
20
16
20
22
20
18
20
18
20
14
20
14
20
12
20
16
20
22
20
22
20
16
20
22
20
22
20
22
20
22
20
22
20
22
20
16
20
18
20
12
12
12
12
12
12
12
12
N/A
20
32
Cable
One
N/A
22
22
22
22
N/A
22
22
22
22
22
22
22
22
22
22
22
22
22
N/A
22
22
N/A
22
22
N/A
N/A
22
22
N/A
22
N/A
22
N/A
N/A
22
22
22
22
22
22
N/A
22
22
N/A
N/A
N/A
22
N/A
22
20
20
N/A
20
N/A
Table 12 – Connector Four, Cables One, Two and Three Wire Shielding Groups
Cable Two and Three
Signal
Wire Return,
Probe Short I &
"W" Open Circuit
Shield
Sync I &
Sync 2
Shield
Open
Circuit
Connector Four
Signal
Cable One
Signal
Data Enable
Data Enable Complement
Data Enable
Data Enable Complement
Data Enable
Data Enable Complement
Data Device to System One
Data Device to System One Complement
Data Device to System One
Data Device to System One Complement
Data Device to System One
Data Device to System One Complement
Data System One to Device
Data System One to Device Complement
Data System One to Device
Data System One to Device Complement
Data System One to Device
Data System One to Device Complement
Data Clock
Data Clock Complement
Data Clock
Data Clock Complement
AC Operational Power, Phase A
AC Operational Power, Phase B
AC Operational Power, Phase, C
AC Operational Power, Phase N
Data Clock
Data Clock Complement
DC Operational Power Return
DC Operational Power
DC Operational Power Return
Enclosure Return
Energize Order ACC
AC Operational
Power Phase, A
AC Operational
Power Phase, B
AC Operational
Power Phase, C
AC Operational Power Phase,
N
DC Operational Power Return
AC Operational
Power Phase, A
AC Operational
Power Phase, B
AC Operational Power Phase, C
Enclosure Return
Enclosure Return
Energize Order AC
Energize Order ACC
Energize Order AC
Start ACC
Identification Power
Identification Bit 0
Identification Bit 1
Probe Short I
"W" Open Circuit
Identification Bit 2
Device Monitor
Start AC
Data Ground Reference
Device Downloader 2
Wire Return
Sync I
Wire Return
Sync 2
Sync I
Open Circuit "K"
Open Circuit "AC"
Open Circuit "E"
Open Circuit "AE"
33
Wire Return
Start ACC
Connector Two
Start ACC
Start AC
Connector One
Start AC
Device Monitor
Connector Four Output (E-1)
Device Monitor
Connector Four Input (E-2)
"N" Open Circuit
Data Ground
Reference &
Device
Downloader 2
Shield
Identification Device Monitor
Shield
& Start Shield
Enclosure
Return, Energize
DC Power
Order & "N"
Shield
Open Circuit
Shield
AC Power
Shield
Data Shield
Shield Group
Several wires internal to connector four that connect the leads from cable one to cable
two are different gauges than the interfacing cable wires. In addition, the shielding
configurations between connector four, cables one, two and three are not the same. The
data shield groups are shielded consistently through all cables. AC power shield is
grouped together in cables two and three and in cable one with the exception of phase, N
(neutral phase) and each phase is shielded individually in connector four. DC operational
power return is shielded by itself in cables two and three and connector four is shielded
with DC operational power return in cable one. Enclosure return, energize order AC and
energize order ACC are shielded together in cables one, two and three however,
enclosure return and “N” open circuit are shielded together in connector four and
energize order AC and energize order ACC are not shielded. Device monitor, start AC
and start ACC have the same shielding configurations between all cables and are
shielded individually in connector four. There are no identification signals, data link
ground reference and device downloader 2 shielding in the cables and identification
power, identification bits 0, 1 and 2, data link ground reference and device downloader 2
are shielded in connector four. The wire return is shielded by itself in the cables and is
shielded with probe short 1 and “W” open circuit where probe short 1 and “W” open
circuit are not shielded in the cables. Sync 1 and 2 are shielded together in cables two
and three and are not shielded in cable one. Sync 1 is shielded by itself in connector four.
Lastly, open circuits “K” and “E” are shielded individually in cables two and three and
open circuits “AC” and “AE” are shielded individually in connector four. There are no
shielded open circuits in cable one. Table 13 compares the grounding configurations
between cables one, two and three and connector four.
Table 13 - Connector Four, Cables One, Two and Three Grounding Pins
Cable/Connector
Cable One
Connector
Four
Shield Grounding Pin(s)
A&Y
E-1 to E-2 A
J1
Cable Two and Three
No Grounding
A
34
Notes
Pin A - Data Shield Carry Through
Pin Y - Data Ground Reference
E1 and E2 are the connections to
connector one and cable two
respectively. J1 is a connection for test
equipment.
None
Cable one shield grounding pins are A and Y. Pin A is the data shield carry through and
pin Y is the data link ground reference which is grounded to chassis. Connector four
shields for the wires connecting E-1 to E-2 is pin A and the shields on J-1 are not
grounded. Cables two and three wire shields are grounded to pin A.
With the knowledge of these differences, connector four was further investigated in an
actual use environment. Connector four was chosen to be investigated first because it is
not part of the baseline configuration. Troubleshooting was completed and it was
determined that when connector four was installed the simulators did not emulate the
device as expected and when connector four was not installed the simulators did emulate
the device as expected.
The analysis identified that there are significant differences between cables one, two and
three and connector four. The wire gauging, shielding and grounding configurations that
are different affected the simulators ability to emulate the device. Adding connector four
in line in order to measure signal voltages, currents, frequencies and extract data,
changes the baseline configuration of the systems and components. Components that are
added or modified to the baseline configuration in order to allow for the operation of a
simulator affect the validity of the simulation. This leads to capabilities and limitations
to each simulator.
8.6 Capabilities and Limitations of Simulators
As discussed in the introduction to modeling and simulation section of the report, early
in a system development, simulators are fairly simple and fidelity typically grows as the
system matures. In the case of simulator one, two and three, the device that they are
emulating is maturely developed and the simulators use different methods to emulate the
device. Simulator two uses only software and functions, simulator one uses a
combination of software and hardware and simulator three uses hardware. Simulator one
and three are examples of SIL/HWIL that develop the most realistic simulation of the
device. Because of the different configurations, each simulator has advantages and
disadvantages for their use in system development, test and evaluation and in training
35
8.6.1
System Development
Both simulator one and three can be used in testing software development for the device.
Simulator one and three include a CB which houses the actual device circuit cards.
Software can be downloaded into the CB and compatibility testing can be done to ensure
the software operates as expected with system one during state one. However, unlike
simulator one, simulator three uses an actual Comp 1, Comp 2 and regulator which does
not allow for state two testing.
System development requires data collection. Simulator one and three can integrate
connector four and utilize the interface test set data collection tool to meet this
requirement. Since simulator two emulates the CB, Comp 1, Comp 2 and regulator
components it would not be the preferred option for system development.
8.6.2 Test and Evaluation
All three simulators can be used in test and evaluation. To allow for the collection of
data for simulator one and three, connector four must be installed to connect the
interface test set computer. Simulator two can collect a limited amount of data including
performance monitoring and fault localization of circuits and functions that can be
detected by system one. In addition, simulator two displays all voltages received from
system one to simulator two for troubleshooting and can determine that all internal
power supply voltages are within tolerance. However, if additional data is required,
connector four and interface test set data collection computer must be installed.
There are limitations to the use of each simulator in test and evaluation. Table 14
identifies the differences in components and cabling between the baseline device
configuration and each simulator.
36
Table 14 – Comparison of Simulator Components to Baseline Configuration
Device
Cable One
Internal
Internal
Connector
Wire Two Regulator
Cabling Connectors
Two
Simulator One
Modified
Modified
Modified
Modified
None
Simulator Two
Modified
Modified
Modified
Modified
Simulator Three
Actual
Actual
Actual
Actual
CB
Comp 3
Simulated
Actual
Actual
None
Simulated
Simulated
Actual
Actual
Actual
Comp 1
Comp 2
Simulated Simulated
Simulated Simulated Simulated
Actual
Actual
Actual
Both simulator one and two use a modified cable one, internal cabling, internal
connectors and connector two whereas simulator three uses actual components.
Simulator one and two use a simulated regulator, Comp 1 and Comp 2 where simulator
three uses actual components. Simulator three includes wire two where simulator one
and two do not. Lastly, simulator one and three uses an actual CB and Comp 3 where
simulator two simulates these components.
The differences between the simulators and the baseline device limit the simulators
capability of emulating the device. Electrical characteristics including power loads,
grounding, resistance/impedance, inductance and capacitance change as components are
modified or simulated. These factors should be taken into account when determining the
desired fidelity level in testing system one to device interface.
8.6.3 Training
Simulator two is readily installed in an actual use environment which allows for creation
of training scenarios. Both simulator one and three require installation prior to training.
In addition, simulator one and two are capable of both state one and state two training
where simulator three is only capable of state one training.
37
9. Conclusion
This report is an investigation on why simulators did not emulate a device properly. The
investigation followed a military problem solving method. Major areas of the possible
causes were identified and facts were gathered on the baseline configuration and the
simulators. A criterion was developed by comparing installed simulator configurations
with the baseline configuration and a fishbone diagram was used to organize the
potential causes of the problem. Lastly, through process of elimination, it was concluded
that connector four, which was not an operational component, but a component used for
test and evaluation data extraction changed the baseline configuration with respect to
wire gauging, shielding and grounding thus effecting the ability of the simulators to
emulate the device. Connector four affected the performance of the simulators and the
simulators operated as expected when connector four was absent. Installing or using
components that are not used in the baseline configuration adds uncertainty to the
validity of the results given by a simulator. Modified baselines should be taken into
account when using simulators in systems development, test and evaluation and training.
To create higher fidelity and confidence level emulations, actual components from the
device should be used to the maximum extent possible.
38
Appendix A – Interface Signals
This section provides a background to the interface signals transferred between system
one and the device through cables one, two and three.
System One to Device Signals
AC Operational Power
Phase A, B and C, four wire including phase N, WYE connected power for operation of
the major equipment internal to the device prior to state two.
Energize Order
A power and triggering signal to the device to activate the final preparations for state
two, including activation of the internal components.
Wire Return
A ground return path for the device wire one test. Cable one is required to conduct state
one wire one testing to provide a return path to system one.
Start
Is a signal that enables the start function and also initiates internal state two processing
in the device.
Identification Power
Power to the device to be used for generation of the identification bit signals. The
identification bit signals are used to determine which configuration of device is
connected.
28VDC Operational Power
Power used to enable certain power supplies internal to the device and to control certain
state one sequences within the device. Absence of the proper identification bit signals
from the device shall inhibit application of this power to the device.
39
Digital Data Signals
Multiple digital signals that are transferred to the device that provides information such
as presets and data prior to state two.
System One to Device Signal Connector and Pin Identification
Table 15 identifies the pins that are used in the connectors for the transfer of data from
system one to the device.
Table 15 – System One to the Device Signal Connector and Pin Identification
Connector one Pin
Device connector two
Signal
Pin
F
C, AC
AC Operational Power, Phase A
G
D, AD
AC Operational Power, Phase B
E
E, AE
AC Operational Power, Phase C
D
L, AF
AC Operational Power, Phase N
T
L, U
Energize Order AC
B
C, B
Energize Order ACC
V
W
Wire return
W
H
Start AC
Z
Z
Start ACC
U
N
Identification Power
T
G
28 VDC Operational Power
P
P
Digital Data Signals
Y
X
Digital Data Signals Complement
Device to System One Signals
Device Monitor
A signal from the device to system one indicating completion of the initialization tests,
continuity of cabling in the device and successful completion of digital safety tests.
40
Enclosure Return
A signal from the device to system one derived from the energize order signal signifying
that the device is on internal power, has valid presets and continuous inputs, and is ready
in all respects for system one to terminate normal state one inputs and enter state two.
Identification Bit 0
A signal from the device to system one derived from the identification power by looping
the power back to system one. The signal is present for all versions of the device. The
signal is terminated when the identification power is terminated.
Identification Bit 1
A signal from the device to system one is derived from the identification power by
looping the power back to system one. The signal is to be an open circuit for all versions
of the device. The signal is terminated when the identification power is terminated.
Identification Bit 2
A signal from the device to system one is derived from the identification power by
looping the power back to system one. The signal is to be an open circuit for a second
secondary version of the device and is to be present for all other versions of the device.
The signal is terminated when the identification power is terminated.
Identification Bit 3
A signal from the device to system one is derived from the identification power by
looping the power back to system one. The signal is to be an open circuit for all versions
of the Device. The signal is terminated when the identification power is terminated.
Identification Bit 4
A signal from the device to system one is derived from the identification power by
looping power back to system one. The signal is to be an open circuit for the primary
41
versions of the device and is to be present for the secondary versions of the device. The
signal is terminated when the identification power is terminated.
Identification Bit 5
A signal from the device to system one is derived from the identification power by
looping the power back to system one. The signal is to be an open circuit for all version
of the device. The signal is terminated when the identification power is terminated.
Digital Data Signals
Multiple digital signals that are transferred to system one provides information such as
status and responses to inputs.
Device to System One Signal Connector and Pin Identification
Table 16 identifies the pins that are used in the connectors for the transfer of data from
system one to the device.
Table 16 – Device to System One Signal Connector and Pin Identification
Connector one Pin
Device connector two Pin
Signal
M
AJ
X
D, M
C
AL
Identification Bit 0
L
W
Identification Bit 1
V
S
Identification Bit 2
AK
F
Identification Bit 3
G
I
Identification Bit 4
AH
-
Identification Bit 5
R
E
Digital Data Signals
Z
F
Digital Data Signals Complement
Device Monitor
Enclosure Return
42
Appendix B – Principles of Electrical Engineering
Fundamentals of Electronics
The purpose of this section is to briefly touch upon fundamentals of electronics that will
be discussed in the report.
Current
Current consists of the flow of very large numbers of charged particles through a
conductor. These charged particles are electrons and protons which are commonly
referred to as elementary charges. Electric current is defined as the time rate of change
of charge passing through a predetermined area5. Electric current is measured in amperes
or amp.
Voltage
A voltage, or potential difference, between two points in a circuit indicates the energy
required to move charge from one point to another5. The voltage is a measure of the
driving force for the flow of current through a circuit or conductor. This potential
difference is measured in a unit called volt.
Resistance
When electric current flows through a conductor it encounters a certain amount of
resistance. Resistance is the opposition to current that is provided by the conductor6.
This resistance is measures in a unit called ohms.
Direct Current
Direct current is the flow of charge in one direction through a conductor. As shown in
Figure 13, the current flows in one direction through the circuit and is constant in
magnitude and direction.
43
Figure 13 – Direct Current6
Alternating Current
Alternating current is bi-directional, meaning that the flow of charge changes direction
periodically6. As shown in Figure 14, the magnitude and direction of the current are not
constant. From period t0 to t1 the current is positive and the flow in the circuit is
clockwise. From period t1 to t2 the current is negative and the flow in the circuit is
counter-clockwise.
Figure 14 – Alternating Current6
Three Phase Power
Three phase power is produced when three sinusoidal voltages that are shown in Figure
14 are generated 120o out of phase with one another. Advantages of three phases over
single phase power include increased efficiency and constant supply of power.
44
Three Phase Power Delta and WYE Connections
Three phase delta and WYE connections are two different arrangements where
alternating current sources are connected. Figure 15 shows a delta configuration on the
left and a WYE configuration on the right.
Figure 15 – Delta and WYE Configurations5
Fundamentals of Circuitry
Energy Storage in Circuits
Capacitance and Inductance are two methods for energy storage in a circuit. Both these
methods store energy in an electromagnetic field. Two electrical components that can
induce capacitance and inductance in a circuit are called capacitors and inductors,
respectively.
Capacitors
The most basic type of capacitor is constructed with two parallel plates and is separated
by an insulating material, as shown in Figure 16. In a DC circuit a capacitor acts as an
open in the circuit.
Figure 16 – Capacitor Construction6
45
Inductance
Inductance occurs when a magnetic field produced by a voltage and current in a
conductor induces a voltage and current in a nearby conductor.
Ground
Ground represents a specific reference voltage that is usually a clearly identified point in
a circuit and that a voltage can be measured from.
Cabling
Shield
A shield is a material made of a metallic foil or braid that is wrapped around a conductor
to contain electrical energy. The shield protects the signal on the cable from radiating
and interfering with signals in other nearby cables and circuitry.
Signals
Electromagnetic Interference
Electromagnetic interference is when a combination of electric fields produced by a
voltage and magnetic fields produced by a current flow in a conductor interfere with a
nearby conductor.
Schematic Symbols
Table 17 identifies schematic symbols
Table 17 – Schematic Symbols7
Wires
Connected
Ground
Symbols
Coaxial
Cable or
Shielded
Line
46
Shielded
Conductor
Shielded MultiConductor
Cable
REFERENCES
1
"Military Science." MSL 200 Textbook -. University of California, Davis Campus, n.d.
Web. 11 Sept. 2014.
2
Raytheon. "Technology Today." Raytheon's Modeling and Simulation 1 (2013): 1+.
Web.
3
"Understanding Advanced System Integration Labs: Simulation-Centric System
Integration." Applied Dynamics International (2007): 1-12. Web. 23 Oct. 2014.
4
"ASWTT." Joint Warfare Simulator. Eca SINDEL, 2010. Web. 24 Oct. 2014.
5
Rizzoni, Giorgio. Principles and Applications of Electrical Engineering. Boston:
McGraw-Hill Higher Education, 2007. Print.
6
Paynter, Robert T., and B. J. Toby. Boydell. Electronics Technology Fundamentals:
Conventional Flow Version. Upper Saddle River, NJ: Pearson/Prentice Hall, 2005. Print.
7
Electronics Symbols." Northwest-Shoals Community College. National Science
Foundation, n.d. Web. 1 Nov. 2014.
47