What is Custom Firmware Development & The Role of Custom Firmware in Aerospace & Defense Applications

Prepared by Paul Greenwood, Senior Principal Engineer, VORAGO Technologies.
October 2, 2023

Introduction: What is custom firmware?

In the ever-advancing landscape of aerospace and defense, technological innovation is not only a symbol of progress but also a cornerstone of safety, reliability, and precision. Beneath the surface of high-flying aircraft, sophisticated spacecraft, and cutting-edge defense systems lies a silent yet indispensable force driving the seamless operation of these sectors: custom firmware solutions. Custom firmware is a new or modified version of firmware created by third parties to provide new features or to unlock hidden functionality. These intricate lines of code are meticulously tailored to meet the demanding requirements of these industries, serving as the digital architects that power the most advanced machinery and systems. In this in-depth exploration, we will journey into the realm of custom firmware solutions for aerospace and defense applications. We will uncover their multifaceted roles, delve into the challenges they overcome, and extract the invaluable lessons they impart.

What does custom firmware do for Aerospace and Defense?

In the realm of aerospace and defense, where precision, performance, and security are paramount, custom firmware solutions play a pivotal role. These solutions provide tailored software intricately designed to cater to the unique and complex needs of these industries. Serving as digital conductors, custom firmware orchestrates the intricate functions of avionics systems, communication networks, guidance, control systems, and more. In the context of aircraft, custom firmware ensures that flight dynamics are managed with utmost precision. Furthermore, it plays a critical role in managing communication and navigation systems, both of which are essential for the success of commercial and military aviation operations.

What is an example of custom firmware?

An illustrative example of custom firmware in space applications is the software that powers robotic arms and manipulators on space rovers and spacecraft. These sophisticated mechanisms enable the manipulation of objects, the collection of samples, and the execution of intricate tasks in the challenging environment of space. Custom firmware is instrumental in ensuring the precise control and operation of these robotic systems, allowing them to perform tasks that would otherwise be impossible for human operators due to the remoteness and harsh conditions of space.

Consider the case of a space rover deployed to explore the surface of a distant planet. This rover is equipped with a robotic arm that can extend, retract, rotate, and articulate its joints, mimicking the movements of a human arm. The custom firmware developed for the robotic arm is tailored to its specific design and capabilities:

• Motion Control: The firmware governs the precise movements of each joint of the robotic arm. Algorithms within the firmware translate high-level commands from mission operators into motor control signals that enable the arm to reach specific positions and orientations.

• Force Feedback: In some cases, the robotic arm needs to exert controlled force while interacting with its environment. The custom firmware can incorporate force feedback mechanisms that enable the arm to sense resistance or contact with objects.

• Autonomous Manipulation: Due to the communication delay between Earth and space, some tasks require the robotic arm to operate autonomously. The custom firmware can include algorithms for autonomous manipulation, enabling the arm to adapt to unexpected situations and make real-time decisions based on its surroundings.

• Collision Avoidance: Space environments can be cluttered with obstacles, and the robotic arm must avoid collisions while moving. The firmware can incorporate collision detection and avoidance algorithms that use sensors to detect potential obstructions and adjust the arm's trajectory accordingly.

• Calibration and Compensation: In the vacuum and extreme temperature conditions of space, mechanical components can experience slight deviations from their expected behavior. Custom firmware programming can include calibration routines that ensure the robotic arm's movements remain accurate over time, compensating for any changes in its mechanical properties.

• Teleoperation: While autonomous operations are essential, human operators can also teleoperate the robotic arm for tasks that require human judgment. The firmware includes interfaces that translate operator inputs into robotic arm movements, facilitating real-time remote control from mission control centers on Earth.

The example of robotic arms on space rovers showcases how custom firmware is tailored to the specific requirements of space applications. These firmware solutions enable the robotic arms to execute complex tasks, interact with their environment, and contribute valuable data to scientific exploration and discovery. The ability to control robotic systems remotely in the harsh and distant realm of space is a testament to the power of custom firmware in enabling humanity to explore and understand the cosmos.

The role of custom firmware in space applications?

The challenges posed by the vast expanse of space are unique and formidable. Communication delays, extreme temperatures, and the presence of radiation are just a few of the obstacles spacecraft must navigate. In this context, the role of custom firmware becomes even more critical. It oversees satellite communication, navigational systems, scientific instruments, and virtually every aspect of spacecraft operations. With communication delays extending to minutes or even hours, custom firmware ensures efficient data transmission across vast distances, enabling scientists and engineers to gather insights from the farthest reaches of the cosmos. Moreover, these firmware solutions empower systems to adapt and thrive in the unforgiving environment of space, where temperatures swing dramatically, and the vacuum is permeated by radiation.

Lessons learned from the custom firmware development process.

The journey of developing custom firmware solutions for aerospace and defense applications imparts invaluable lessons. The stringent demands of these industries cultivate a rigorous approach to testing. Firmware must function flawlessly under a spectrum of scenarios, from standard operations to extreme conditions. This exacting testing regimen underscores the unwavering commitment to reliability and performance. Moreover, the need for redundancy emerges as a fundamental principle. Aerospace and defense sectors recognize that a single point of failure can have catastrophic consequences. Therefore, an unwavering emphasis is placed on the implementation of backup systems and comprehensive contingency plans. These lessons, born from the challenges of aerospace and defense, possess universal applicability, underscoring the importance of robust software development practices in any context.

Advantages of outsourcing custom firmware development services vs in-house

Organizations operating within the aerospace and defense sectors frequently grapple with a pivotal decision: whether to outsource embedded firmware development to a firmware development company or build an in-house team. The decision to outsource or develop in-house hinges on a multitude of factors, including project complexity, timeline constraints, budget considerations, and the strategic direction of the organization.  Outsourcing firmware development offers access to specialized expertise that may not be readily available within the organization. This approach can expedite time-to-market and potentially alleviate financial constraints.

Developing custom firmware for microcontrollers

At the core of numerous aerospace and defense systems are microcontrollers—compact devices that serve as the central hub of various operations. Developing custom firmware for microcontrollers requires a profound understanding of their architecture, capabilities, and limitations. Crafting optimal code is paramount to ensure the efficient utilization of limited resources, particularly in battery-powered applications where power efficiency directly impacts operational longevity. Furthermore, compatibility with other hardware components and stringent adherence to communication protocols are imperative for seamless integration within larger systems.

Typical microcontroller firmware layout

The architecture of microcontroller firmware adheres to a structured layout comprising several pivotal components. Initialization routines configure the microcontroller's hardware, while interrupt handlers manage asynchronous events, ensuring swift responses to critical signals. Communication protocols facilitate seamless data exchange, enabling harmonious interaction with other devices. The essence of the firmware resides in its application-specific logic, where custom code governs the intended functionality. Organizing firmware components in a structured manner enhances maintainability, simplifies troubleshooting, and paves the way for future enhancements.

Challenges of custom firmware development

While the benefits of custom firmware solutions are substantial, the journey of their development is not devoid of challenges. Striking a delicate balance between performance and power efficiency is paramount, particularly in applications reliant on battery power. Adherence to stringent regulations, encompassing safety and security standards, is non-negotiable. Moreover, in an ever-evolving technological landscape, developers must remain vigilant against emerging security vulnerabilities, necessitating a perpetual cycle of updates and enhancements.

Conclusion

In the aerospace and defense sectors, where precision, security, and reliability are paramount, custom firmware solutions emerge as the unsung heroes. Their intricate role in controlling systems, ensuring communication, and facilitating mission success is fundamental to the advancement of these industries. As technology continues to evolve, so will the complexity and demands of custom firmware development. Mastering this art will remain pivotal in shaping the future of aerospace and defense, pushing humanity towards new horizons while safeguarding our world with the utmost care and expertise.

VORAGO Technologies provides custom firmware solutions for its portfolio of radiation hardened microcontrollers.  To request information about VORAGO’s rad-hard MCUs or get a quote for custom firmware development, visit https://www.voragotech.com/contact-us.