With the increasing requirements for cabin comfort, safety, and reliability in modern aircraft, the Environmental Control System (ECS) plays a critical role in regulating cabin temperature, pressure, airflow, and air quality. The Environmental Control Computer (ECC), as the core control unit of ECS, is responsible for complex environmental regulation and cross-system coordination. Traditional testing methods rely heavily on physical test benches for functional verification and interface testing, which are time-consuming, costly, and lack flexibility. To address these challenges, the Environmental Control Computer Integrated Test Solution has been developed, combining Hardware-in-the-Loop (HIL) simulation with real hardware testing to provide a comprehensive test platform that supports ECC prototype development, software debugging, functional verification, and final delivery.

The system delivers both internal and external excitation signals for the ECS, simulating avionics, electro-mechanical, and other integrated systems while collecting real-time outputs from the ECC to build an environmental model for closed-loop simulation and verification. The HIL simulation mode allows dynamic response simulation at lower cost, reducing the need for extensive physical test benches, minimizing experimental risks, and shortening test cycles. The system also supports physical testing with a scaled test cabin that houses full ECC components with interfaces identical to those on aircraft, covering cabin pressures from 15 to 130 kPa to meet various operational conditions.

The ECC integrated test system offers wide-ranging capabilities, including software development and debugging, open-loop interface testing, closed-loop dynamic testing, and digital cockpit simulation to replicate cabin and cargo temperature and pressure dynamics. It can test peripheral components such as cabin pressure actuators (exhaust valves, balance valves, safety valves) and cabin pressure sensors, ensuring the ECC responds correctly under different power modes and during normal or emergency power transitions. The platform generates external excitation signals and records device outputs in real-time to form closed-loop feedback simulations, ensuring ECC performance can be verified under both digital and physical cabin conditions.

Functionally, the system supports comprehensive interface testing, including automated mechanical and electrical interface checks. Digital cockpit testing capabilities simulate temperature, pressure, and airflow variations to validate ECC control logic and performance. An embedded ECS model library allows the system to compare physical test cabin results with digital simulation outputs, applying dynamic identification to correct models, progressively aligning HIL results with full physical test outcomes for higher reliability and accuracy.

This solution is suitable for subsystem acceptance testing of aircraft ECS units, interface verification for finished components and sensors, and bus transmission functionality testing. It not only supports ECC software development and debugging but also provides high-fidelity closed-loop simulation verification, offering robust test assurance throughout ECS design, production, and delivery phases.