innovative sustainment of adf helicopter structural integrity
TRANSCRIPT
![Page 1: Innovative Sustainment of ADF Helicopter Structural Integrity](https://reader034.vdocuments.net/reader034/viewer/2022042519/6261c39cf853c852464926e9/html5/thumbnails/1.jpg)
Innovative Sustainment of ADF Helicopter Structural Integrity
March 2019
![Page 2: Innovative Sustainment of ADF Helicopter Structural Integrity](https://reader034.vdocuments.net/reader034/viewer/2022042519/6261c39cf853c852464926e9/html5/thumbnails/2.jpg)
Outline
1 Fatigue Management - Helicopters
2 Fixed Wing vs Rotary Wing
3 Traditional Helicopter Usage Monitoring
4 Flight Manoeuvre Recognition
5 Extending Component Retirement Times
6 Risk Assessment
7 Condition Data and Corrosion Sensors
8 Being a Smart Customer
9 Loads and Vibration
2 Innovative Sustainment | March 2019
![Page 3: Innovative Sustainment of ADF Helicopter Structural Integrity](https://reader034.vdocuments.net/reader034/viewer/2022042519/6261c39cf853c852464926e9/html5/thumbnails/3.jpg)
• Design and Fatigue Life Assumptions
– Understanding the design assumptions
– Testing assumptions through usage monitoring
– Measuring fatigue drivers
– What is the aircraft condition telling us?
• Component Retirement Times (CRTs)
– Safe life
– Assumptions made when calculating CRTs
• Design Usage Spectrum
– Composite worst case usage spectrum
– Load spectrum and manoeuvres
– Measuring complicated fatigue drivers
Fatigue Management - Helicopters
3 Innovative Sustainment | March 2019
![Page 4: Innovative Sustainment of ADF Helicopter Structural Integrity](https://reader034.vdocuments.net/reader034/viewer/2022042519/6261c39cf853c852464926e9/html5/thumbnails/4.jpg)
Fixed Wing vs Rotary Wing
4
• High Cycle fatigue
– Loads on dynamic components for each rotation of
the rotor
– Small changes in stress = large change in number
of cycles
• Critical components replaced
• Complex DUS
– Expressed as a percentage of flight time
– Less severe for one component may be more
severe for another component
• Asymmetrical Loads
– Left hands turns more damaging than right hand
turns for some components due to rotational forces
• Lack of access to lifing substantiation
S
n
Innovative Sustainment | March 2019
![Page 5: Innovative Sustainment of ADF Helicopter Structural Integrity](https://reader034.vdocuments.net/reader034/viewer/2022042519/6261c39cf853c852464926e9/html5/thumbnails/5.jpg)
Traditional Helicopter Usage Monitoring
5
• Many fatigue drivers are difficult to
record / measure
• Manually record a limited number of
fatigue drivers
– Even simple fatigue drivers are difficult to
record accurately
• Critical Structure consists of rotating
components
– Loads are often difficult to measure
• Compare to DUS which may be poorly
described
• Improving UM through Flight
Manoeuvre Recognition
Innovative Sustainment | March 2019
![Page 6: Innovative Sustainment of ADF Helicopter Structural Integrity](https://reader034.vdocuments.net/reader034/viewer/2022042519/6261c39cf853c852464926e9/html5/thumbnails/6.jpg)
Flight Manoeuvre Recognition
6
•Analysis of Usage data to determine actual
flight manoeuvres– Data from Flight Data Recorder or HUMS
– Algorithms match flight data to DUS
manoeuvres
– Tested against flight test data to validate
•FMR outcomes can input to effective
fatigue management– Allows capture of a higher percentage of
fatigue drivers than traditional UM
– Test assumptions made in FM / CRTs
– Requires flight manoeuvres to be linked to
fatigue damage
Innovative Sustainment | March 2019
![Page 7: Innovative Sustainment of ADF Helicopter Structural Integrity](https://reader034.vdocuments.net/reader034/viewer/2022042519/6261c39cf853c852464926e9/html5/thumbnails/7.jpg)
Flight Manoeuvre Recognition
7 Innovative Sustainment | March 2019
![Page 8: Innovative Sustainment of ADF Helicopter Structural Integrity](https://reader034.vdocuments.net/reader034/viewer/2022042519/6261c39cf853c852464926e9/html5/thumbnails/8.jpg)
• Extending Black Hawk CRTs using
AUUS2 Spectrum
– Based on severe Australian Spectrum
– Until recently only used AUUS2 to reduce
lives
– Enable greater flexibility for the SPO
• Black Hawk Risk Assessment
– No access to the required data to
determine if changes apply to our CRE
– Establish level of risk based on available
information
– Determine appropriate approach to reduce
the risk
– Work closely with stakeholders to agree on
appropriate action in light of PWD
Extending CRTs and Risk Assessment
8
Defence Harmonised Risk Matrix
Risk Management in the Defence Aviation Safety Program
AC 003/2018
Innovative Sustainment | March 2019
![Page 9: Innovative Sustainment of ADF Helicopter Structural Integrity](https://reader034.vdocuments.net/reader034/viewer/2022042519/6261c39cf853c852464926e9/html5/thumbnails/9.jpg)
• Insufficient for effective fatigue or
environmental degradation management
• Non marinised helicopters being
deployed on LHDs
• Environmental degradation management
should be addressed before there is an
issue– management and technology perspective
– Improve condition monitoring and
environmental degradation management
• Understanding and managing
degradation prone areas on the aircraft
• Using corrosion sensors and modelling to
predict rates of corrosion
Condition Data and Corrosion Sensors
9 Innovative Sustainment | March 2019
![Page 10: Innovative Sustainment of ADF Helicopter Structural Integrity](https://reader034.vdocuments.net/reader034/viewer/2022042519/6261c39cf853c852464926e9/html5/thumbnails/10.jpg)
• What is the service provider being
contracted to provide?
• Understand your CRE
• Understand the fatigue management
system being employed
• What outputs are you going to get and
what do they mean?
• ASSUMPTIONS –Are they relevant?
Being a Smart Customer
10 Innovative Sustainment | March 2019
![Page 11: Innovative Sustainment of ADF Helicopter Structural Integrity](https://reader034.vdocuments.net/reader034/viewer/2022042519/6261c39cf853c852464926e9/html5/thumbnails/11.jpg)
• Measure critical structure loads on ADF aircraft
• Better understanding of the applicability of OEM Design Usage Spectra
• Input to Romeo SLAP / SLEP
• Understand loads and vibration on the airframe to: – reduce “nuisance” cracking
– avoid just moving the cracking to a new area
Loads and Vibration Monitoring
11 Innovative Sustainment | March 2019
![Page 12: Innovative Sustainment of ADF Helicopter Structural Integrity](https://reader034.vdocuments.net/reader034/viewer/2022042519/6261c39cf853c852464926e9/html5/thumbnails/12.jpg)
12 Innovative Sustainment | March 2019