From Iron Birds to Digital Twins with Engineering Simulators: Toward Virtual Certification

This study proposes a new approach to creating a virtual flight test environment by integrating a digital twin of an iron bird test rig with an engineering flight simulator. Generating digital twins for test rigs in aviation is a rare and innovative approach. The engineering flight simulator used in this study incorporates real hands-on throttle and stick to provide pilots with a realistic experience. A validated iron bird of a trainer aircraft, a fully equipped test rig encompassing hydraulic, mechanical, flight control, and landing gear systems, was used as the basis for generating its digital twin. This digital twin was then used to update the mathematical model of an actuator, which is a critical component of the flight model operating within the engineering flight simulator. This method produced a highly accurate simulation of flight characteristics for the selected case, and the Flight Simulation Training Device Guideline of the European Union Aviation Safety Agency has been used to ensure the accuracy of this flight model. To demonstrate this concept, a real-world certification test scenario was selected, and the results of the simulator flight tests were compared with the real flight tests. Finally, the study presents a preliminary roadmap for implementing flight test concepts in virtual environments, emphasizing their potential to revolutionize the certification process.