Modern defense systems consist of a multitude of interconnected components. Mechanics, electronics, sensor technology, and software are closely interlinked. Examples include turrets on armored vehicles, guided missiles, autonomous military vehicles, and mobile radar platforms.
Developing such systems is technically demanding. A key challenge lies in integrating the many subsystems, as individual components often come from different suppliers and are only brought together relatively late in the project. It is often at this point that it becomes clear for the first time whether the mechanics, sensors, and control software actually work together reliably.
This raises a fundamental question:
How can complex defense systems be tested before all components are physically available?
One increasingly used method is physics-based real-time simulation. In this approach, the behavior of mechanical systems is modeled using physical models. These models can be run in real time and realistically simulate forces, movements, and interactions.
For example, physics-based simulation makes it possible to analyze the turret movements and stabilization systems of a combat turret at an early stage. The flight dynamics of guided missiles, the vehicle dynamics of autonomous military vehicles, and the movements of manipulators and robotic arms can also be analyzed in this way.
Another important question is:
Can control software be tested before the actual hardware is fully available?
This is where digital twins come into play. A digital twin is a physical simulation model of a system that replicates its behavior as realistically as possible. When this model is connected to the control software, the software can be tested as if it were already connected to the real system.
This allows functions, control strategies, and system responses to be examined as early as the initial development phases.
Simulation also plays a key role in the integration of various subsystems. In many projects, the practical question arises:
How can components from different suppliers be tested together at an early stage?
Virtual integration environments offer a solution here. For example, a turret can be simulated together with its control software even before the complete vehicle exists. Similarly, missile launchers –including hydraulic systems – or sensor systems for autonomous vehicles can be tested in a shared simulation environment.
A particularly common method here is hardware-in-the-loop (HiL) simulation.
In this process, a physical simulation model runs in real time while real control hardware is connected. For the control system, the simulation model behaves as if it were the real system. In this way, the interaction between software, control systems, and physical behavior can be tested without the need for the complete system to be physically present.
As the complexity of modern defense systems increases, simulation is therefore becoming increasingly important. It supports developers in system integration, in testing control software, and in analyzing complex system behavior.
Physics-based real-time simulation and digital twins help identify technical interdependencies early on and reduce risks during development. Especially for complex military platforms, simulation can help identify problems in the early stages of a project and better safeguard development processes.
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