The European Space Agency (ESA) has introduced a highly realistic virtual model, or 'digital twin,' of its Large Space Simulator. Developed by the Spanish engineering firm Empresarios Agrupados, this new software aims to significantly shorten the complex and lengthy training process for operators of Europe's largest vacuum chamber.
The digital twin provides a safe, controlled environment where trainees can learn to manage the facility, practice complex procedures, and even respond to simulated emergencies without risking damage to the actual multi-million-dollar equipment.
Key Takeaways
- ESA has launched a digital twin for its Large Space Simulator (LSS) to train operators.
- The system was developed by Spanish firm Empresarios Agrupados using their EcosimPro software.
- It addresses the challenge of long training times, which can take years due to the facility's complexity and infrequent use (2-3 tests per year).
- The simulator allows for safe practice, including the simulation of equipment failures.
- Beyond training, the tool will be used for virtual testing of upgrades, optimizing resource consumption, and rehearsing test procedures.
Addressing a Training Bottleneck
The Large Space Simulator (LSS), located at ESA’s Test Centre in the Netherlands, is a critical piece of infrastructure. It replicates the harsh conditions of space to test spacecraft before they are launched into orbit. However, operating such a complex facility requires extensive expertise.
According to Remko Moeys, the ESA engineer leading the project, the learning curve for new operators is steep. "The facility is very complex, and it takes many years for people to learn how to operate it," he explained. This challenge is compounded by the limited opportunities for hands-on experience.
"We perform only about 2-3 tests per year, which offers very few occasions for a trainee to shadow and learn from an experienced operator."
To overcome this, ESA commissioned the development of a training simulator. The goal was to create a system that functions much like a flight simulator for pilots, providing a realistic and repeatable training experience.
How the Digital Twin Replicates Reality
The new software, developed over nearly two years, is a precise virtual replica of the LSS control systems. It runs on the same monitors used in the actual control room, ensuring that the training environment is as authentic as possible.
"In the digital twin software, a trainee sees the same things on the screen that they would see when operating the real facility, and the data is displayed in the same way as well," Moeys clarified. "Everything underneath has been virtualised."
The Technology Behind the Simulation
The digital twin was built using 'EcosimPro,' a specialized simulation software suite. This platform was also developed by Empresarios Agrupados, initially with ESA's support, to meet the modeling needs of the aerospace industry. Its applications have since expanded to sectors like energy, water, and biomedicine.
When a trainee interacts with the system—for example, by clicking a button to open a valve—the software doesn't send a signal to a physical component. Instead, it opens a 'virtual valve' and calculates the resulting changes in pressure, temperature, and other variables, feeding the simulated data back to the operator's screen in real-time.
Advanced Training Capabilities
The digital twin offers a level of flexibility impossible with the physical facility. Training sessions can be started from any point in a test sequence, paused, or stopped. It can also run faster than real-time to quickly move through long, uneventful phases that might last for hours.
Crucially, the system allows instructors to introduce failures. "We can even introduce a failure into the test, like a valve not opening or air leaking into the vacuum chamber," Moeys noted. "This allows trainees to practice handling all kinds of potential scenarios."
Julien Pioton, an LSS operator and test engineer at European Test Services (ETS), emphasized the value of this safe training environment. "Operating such facilities isn’t without risk. This tool offers a safe and efficient alternative by allowing LSS operators to repeatedly practice specific test phases, build confidence, and refine their skills."
Benefits Beyond Operator Training
The utility of the LSS digital twin extends far beyond its primary role as a training tool. It serves as a powerful analytical platform for the engineering and operations teams.
The software can be used for several other purposes:
- Virtual Testing: Any proposed changes or upgrades to the LSS can be tested in the simulation first to verify their performance before implementation.
- Operational Efficiency: The model can run studies to optimize the facility’s consumption of resources, such as liquid nitrogen.
- Test Rehearsals: Engineers can rehearse complex test operations in advance to ensure a smooth execution during the actual spacecraft test.
- Failure Analysis: It can simulate abnormal operations to better understand how the system would behave in case of an equipment failure.
Miguel Alcázar, Simulation Manager at Empresarios Agrupados, expressed pride in the project's completion. "This wouldn’t be possible without the EcosimPro tools developed by Empresarios Agrupados over the past 25 years," he said, highlighting the long-term development behind the technology.
The Large Space Simulator A Legacy of Innovation
The Large Space Simulator is Europe’s premier facility for environmental spacecraft testing. Standing 15 meters high and 10 meters wide, it is a cavernous chamber capable of simulating the vacuum and extreme temperatures of space.
LSS at a Glance
- Height: 15 meters
- Width: 10 meters
- Capability: High vacuum and temperatures down to -180 °C.
- Solar Simulation: A set of 19 powerful lamps mimics the intense radiation of the sun.
Inside, powerful pumps remove nearly all the air to create a vacuum, while liquid nitrogen circulating through wall panels cools the environment to a frigid -180 °C. A spacecraft mounted on a robotic arm can be rotated to face a powerful beam of light from 19 lamps, simulating how one side heats up in direct sunlight while the other remains freezing cold in shadow.
The facility has a rich history, with its predecessor, the Dynamic Test Chamber, having been completed 50 years ago. Over the past half-century, it has been instrumental in verifying the readiness of countless missions, including recent spacecraft like EarthCARE, Smile, and the test model for Plato. This new digital twin marks the next step in its evolution, ensuring the LSS remains at the forefront of space technology for years to come.