Purpose – Fault tolerant control surface actuation of unmanned aerial systems with take-off weights below 150 kg offers new design challenges due to limitations in mass, weight and cost. Conventional redundancy concepts need to be amended by smart operational strategies, enhanced sensor data provision and advanced failure mitigation. The paper aims for the design of a hardware-in-the-loop platform that enables the model-based development, verification, performance analysis and safety assessment of redundant and smart electromechanical actuators. Design/methodology/approach – The hardware-in-the-loop platform was developed on the basis of various requirements and upcoming certification needs. One major aspect is the close relationship between model-based design approaches and the ability to keep hardware prototypes in the loop during the entire development process using virtual actuator control electronics. Findings – The platform has proven to deliver valuable results during development of hardware and software prototypes. By its high flexibility and modularity, it has shown to be a versatile, attractive and cost-efficient alternative to conventional hardware-in-the-loop environments. Practical implications – The presented simulation environment allows operating the components under realistic conditions by offering a control surface setup with redundant electromechanical actuators and a torque machine for hinge load simulation. It supports active–active, active–passive and single actuator operations to examine force-fighting phenomena, performance measurements and the exposure to actuator and control surface hardware faults. Originality/value – The presented simulation environment provides precise knowledge about the behaviour of all involved components within all states of flight as well as mission and failure scenarios that are required during design, implementation and testing of fault tolerant actuation systems.     «

Purpose – Fault tolerant control surface actuation of unmanned aerial systems with take-off weights below 150 kg offers new design challenges due to limitations in mass, weight and cost. Conventional redundancy concepts need to be amended by smart operational strategies, enhanced sensor data provision and advanced failure mitigation. The paper aims for the design of a hardware-in-the-loop platform that enables the model-based development, verification, performance analysis and safety assessment...     »