Fleet operations, updates and predictive maintenance

A system is delivered once and maintained for a decade. Most of the cost, and nearly all of the risk, is in the second part.

'Fleet' must look like a fleet. One aircraft undermines the whole page.

Updating a fleet without breaking it

Updating one vehicle on a bench is trivial. Updating hundreds of vehicles in the field, across firmware versions, configurations and hardware revisions accumulated over years, without turning one of them into a brick, is not.

We build update and configuration systems with the failure cases designed first: atomic updates that either complete or roll back, recovery that works when an update is interrupted mid-write, verification that the vehicle is running what the fleet record says, and staged rollout so a bad release reaches a handful of units rather than all of them.

Fleet monitoring dashboard: per-node CPU, memory, disk and network gauges above a live system load chart.

Version alignment as a safety property

A fleet whose members are quietly running different firmware is a fleet whose behaviour cannot be predicted, whose incidents cannot be reproduced and whose certification basis is questionable. We treat knowing exactly what every unit is running as a safety property, and build the tooling that keeps it true.

Status page for a single field unit, showing uplink, access point, GNSS base, system health and storage, with

Predicting failures instead of reacting to them

Components rarely fail without warning; they fail without anyone listening. Motor current signatures drift, cell impedance rises, vibration spectra change, thermal behaviour shifts — usually well before the failure.

We build monitoring that models normal behaviour for each specific airframe and flags departure from it, so maintenance is scheduled against evidence rather than against a calendar or an incident. The aim is a warning several flight hours before the failure, with enough specificity to name the component.

What you get

  • Fleet-wide updates with a rollback path and no bricked units
  • Certainty about what every unit in the field is running
  • Maintenance driven by measured condition, not by calendar or incident

Related work

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