structural health management: a rotorcraft oem...
TRANSCRIPT
Structural Health Management:
A Rotorcraft OEM Perspective
Mark Davis
Tech Fellow, Prognostics & Health Management
Sikorsky Aircraft Corporation (SAC)
10th International Workshop on Structural Health Monitoring
Palo Alto, CA
September 1, 2105
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Copyright Notice
This document, or an embodiment of it in any media, discloses information which is proprietary, is the property of Sikorsky Aircraft Corporation, is an unpublished work protected under applicable copyright laws, and is delivered on the express condition that it is not to be used, disclosed, or reproduced, in whole or in part (including reproduction as a derivative work), or used for manufacture for anyone other than sikorsky aircraft corporation without its written consent, and that no right is granted to disclose or so use any information contained therein. All rights reserved. Any act in violation of applicable law may result in civil and criminal penalties.
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OUTLINE
• Aircraft Health Management Vision
• HUMS/IVHMS Evolution and Current Capability
• SAC Experience with SHM
• SHM Assessment & Transition Challenges
• Mechanical Diagnostics Analogy
• Thoughts on a SHM Transition
• Concluding Remarks
2
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SAC HEALTH MANAGEMENT VISION Eliminate Unscheduled Maintenance
Optimize Scheduled Maintenance
Focus Troubleshooting & Reduce False Removals
Maximize Detection Time Before Failure
Enhance Safety
3
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S-92®
CH-53E
S-61™
S-76C++™
CH-53K UH-60A,L,M
VXX
CH-148
SAFETY
MAINTENANCE & TROUBLE SHOOTING
CONDITION BASED MAINTENANCE
SAC HEALTH MANAGEMENT EVOLUTION
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SAC HEALTH MANAGEMENT SYSTEM
S-92® Operators
HUMS Collected
Data Helicopter Flight Data Mgt.
Customer
MFD Ground Station
HUMS Toolbar
Sikorsky
Web Portal KDT
CI Box Plot
MDAT Matlab
Data Transfer
Multiple time a day
Value: new tools, maintenance credits, etc.
Drivetrain
Diagnostics
Rotor Track
& Balance
Exceedance
Display
Proactive Support
HUMS/Maintenance
Data & Field Events
New HUMS
Tools
Retirement
Time
Adjustment
S-92 Hub
Pro-Active
Support
5
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S-92® HUMS Ten years of maturation and value
Downtime Avoidance
High-sensitivity vibe analysis
enabled early detection and
proactive response.
New Detection Capability
Isolated vibe-signature of previously
undetectable pivot bearing issue
and enabled software enhancement
Extended Time-on-Wing
Decision Support
Data mining and analysis to
understand field issues and
improve decision making
Over 250+ aircraft monitored
~750,000 Flight Hours
10GB+ data daily
Analysis & Tool Development
Web Portal
KDT Part Tracker
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Leveraged S-92® Main Rotor Hub
life adjustment to gain additional
retirement time adjustment credits
SAC Ground
Based App
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WHAT IS SHM?
Common Perspective: Structural Health Monitoring
Technologies required to detect, isolate, and characterize
structural damage (e.g., cracks, corrosion, FOD, battle
damage). Typically synonymous with monitoring of airframe
structural damage.
SAC Perspective: Structural Health Management
Holistic cradle-to-grave approach to ensure aircraft structural
integrity, safety, and reliability through optimized balance of
• design conservatism;
• monitoring of usage, loads, and structural damage;
• fleet management of flight critical components
• certification of SHM enabled condition-based maintenance (CBM).
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Copyright © 2015 An Unpublished work by Sikorsky Aircraft Corporation. All rights reserved (see cover page). This document contains no technical data controlled by the ITAR or EAR
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STRUCTURAL HEALTH MANAGEMENT
8
Structural Health Management
Lo
ad
s, U
sag
e,
En
vir
on
me
nta
l
Op
era
tio
na
l H
isto
ry
No
n-d
es
tru
cti
ve
Eva
lua
tio
n a
nd
Vis
ua
l
Insp
ecti
on
s
In-S
itu
Da
mag
e D
ete
cti
on
an
d D
am
ag
e G
row
th
Mo
nit
ori
ng
Pre
dic
tive T
ech
no
log
ies:
Da
ma
ge
gro
wth
/ R
UL
Ma
inte
na
nc
e A
cti
on
s:
Ins
pe
ct,
Re
pa
ir, R
ep
lac
e
Design
Conservatism
Fatigue
Testing
Structural
Analysis
Flight Load
Survey Testing
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ROTORCRAFT SHM CHALLENGES
9
Variability and Complexity of Physics of both Probabilistic & Random Failure Modes Rotor Hub
DamperPitch
ControlRod
Shaft ExtenderBlade Pin
Flap/Lag/Pitch/Thrust Bearing
(inside hub arm)aka elastomeric/MDOF bearing
Rotor Blade
Spindle, Nut, Tie-Rod
Rotor Blade
Cuff Assy
Bifilar Absorber
Pitch Horn
Swashplate(below cowling,attaches to lower PCR end)
Droop Stop
Scissors Assy
Variability of Operational Usage & Loads
Variability of Operational & Maintenance Environments
• Fatigue
• Corrosion
• FOD
• Battle
Typical Failure Modes
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HOLISTIC SHM APPROACH
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USAGE/LOADS MONITORING
Virtual Structural Usage/Loads Monitoring
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Example Key Physical Sensors
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SAMPLE S-92® A/C BENEFITS LLP Retirement Extension (Serial #)
• FAA approved S-92® main rotor (MR) hub life extension based on MR rpm GAG
• Average benefit of 50% one-time CRT extension calculated from first 20 fleet hubs
Data Driven
Inspection
Ro
tor
Sp
ee
d (
rpm
)
50 sec @ 58% RPM
4 min @
39% RPM
2 min @ 50% RPM
Avoid Range
Time
Focused
Troubleshooting
0
20
40
60
80
100
120
140
160
180
0-105 0-110
Rotor RPM Ground Air Ground Cycle
Oc
cu
ra
nc
es
Design
A/C 11
A/C 12
A/C 13
A/C 14
A/C 15
Fleet Avg
Rotor Cycles
0
20
40
60
80
100
120
140
160
180
0-105 0-110
Rotor RPM Ground Air Ground Cycle
Oc
cu
ra
nc
es
Design
A/C 11
A/C 12
A/C 13
A/C 14
A/C 15
Fleet Avg
Rotor Cycles
Component
Retirement
Adjustment
S-92 MR
Hub
Fleet Mean ~ 0.6
STD ~ 0.5
~260 Hours
Left Accessory GBX Bearings
Operator
Alerted
Health AlertsAccessory Gearbox
Accelerometer
Location
Abrasion
Strips replacedInspected No
Fault Found –
Rebalanced
Dis-bonded
Pivot Bearing
Ta
il R
oto
r V
ibra
tio
n (
ips)
Calendar Time
Maintenance Triggers
1/1/20091/1/20081/1/20071/1/2006
3500
3000
2500
2000
1500
1000
500
0
Removal Date
Flig
ht H
ours
at
Rem
oval
Bearing Faulty or worn
Indeterminate
Interference
Scheduled
Vibrations
Code
Scatterplot of Hours on Oil Cooler Blower at Removal Date
Lost Opportunities
Assignable Cause
TBO
Extension
1/1/20091/1/20081/1/20071/1/2006
3500
3000
2500
2000
1500
1000
500
0
Removal Date
Flig
ht H
ours
at
Rem
oval
Bearing Faulty or worn
Indeterminate
Interference
Scheduled
Vibrations
Code
Scatterplot of Hours on Oil Cooler Blower at Removal Date
Lost Opportunities
Assignable Cause
TBO
Extension
TBO Extensions
Clear Outlier
Fleet
Analysis
Level 1 Limit 0.37 G
Level 2 Limit 0.45 G
Level 1 Limit 0.37 G
Level 2 Limit 0.45 G
Anomaly Detection
New Condition
Indicators
Fleet Spectrum Update (Part #) • Virtual Monitoring of Loads (VML) used to calculate TR torque from 500kFH HUMS data
• Load statistics used to revise usage spectrum 3.25X retirement time
• Same approach can be used for serial # credit
TR
Po
we
r (H
P)
Cumulative TR Power Spectrum
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SAC SHM TECH DEVELOPMENT PROGRAMS
13
SIMS IRDT COST-A IHSMS ASTRO RDDT
Tech Assessment
Challenge Problem
Characterization
Metal sub-components
& PSE
Damage detection
sensing validation
Load sensing
evaluation
Prognostic system
architecture
VML extension
Metal PSE
Damage detection
sensing
Damage growth
modeling
Damage tolerant design
framework
Limited composites
VML application
Focus on H-60
Metals only
Damage, corrosion, &
impact detection and
quantification
VML application
Addresses structures,
drives, & rotors
On-board/off-board
system integration
Very focused on
composites
Local damage
propagation modeling
Integration of models
with sensor feedback
Coupon testing for
correlation with models
Focus on CH-53K
composite aircraft
Local / zonal damage
monitoring
Usage & loads
monitoring
Measure load changes
on select primary
structures due to
damage
Reduce over-
maintenance of
composite airframes –
focus on “big damage”
Estimate damage from
fewer sensors
Quantify effect of
damage on load
distribution and DT
Multi-site Damage
Energy Harvester
Load Sensor
Harvester Circuit, Microprocessor, and RF Transmitter
RF Antenna
SIMS Structural Integrity Monitoring System
IRDT Integrated Rotorcraft Damage Tolerance
COST-A Capability-Based Operations Sustainment
Technologies – Aviation
RDDT Rotorcraft Durability and Damage Tolerance
IHSMS Integrated Hybrid Structural Management System
ASTRO Autonomous Sustainment Technologies for Rotorcraft
Operations
2006-9 2008-10 2010-14 2010-13 2012-17 2013-17
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TECHNOLOGY READINESS DEFINITIONS
• System Completed
• Flt / Mission Qual
• System/Subsystem
Development
• Tech Demo
• Tech Development
• Research to Prove
Feasibility
• Basic Research
In Service ……………………………………..
Qualification / Certification ………………….
System Demo ~ Flight Test ….……………….
Sys/Subsys Demo ~ Relevant Lab Environ …
Component~ Relevant Environ …….……….
Component/~ Lab Environ ………….………
Analytical /Exp Proof-of-Concept………….
Technology Concept …………………………
Basic Principles ………………………………
TRL 9
----
TRL 8
----
TRL 7
----
TRL 6
----
TRL 5
----
TRL 4
----
TRL 3
----
TRL 2
----
TRL 1
• Bulk of work in SHM community TRL 3 to 6
• Ok for R&D and at-aircraft monitoring
• TRL-7 required for embedded systems
• TRL-8 required for CBM credits
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Stiffened Bay Panels
Sub-Component RR(Doubler Joint)
Laser
Scribe
Doubler Joint Angle Lap Joint
Sub-Component (TRL 3-5)
• Representative
Features
• Lab transducers, DAQ,
and processors
Beam/Frame Joint Frame Splice Cabin Top-Deck Sub-Assembly
• Full-Scale test articles
• Representative SHM
hardware/software
• Software partially
integrated with
OBS/GBS HUMS/IVHMS
50-100 tests* 20-30 tests*
1-5 tests*
SAC SHM TRL PROGRESSION
1 test*
* Rough number of tests that can be conducted for cost of one sub-assembly test
Full-Scale Primary Structural Elements (PSEs) & Sub-Assemblies (TRL 5-6)
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This research was partially funded by the Government under Agreement No. W911W6-10-2-0006. The U.S. Government is authorized to reproduce and distribute reprints for Government purposes
notwithstanding any copyright notation thereon. The views and conclusions contained in this document are those of the authors and should not be interpreted as representing the official policies,
either expressed or implied, of the Aviation Applied Technology Directorate or the U.S. Government.
CAPABILITY-BASED OPERATION SUSTAINMENT
TECHNOLOGY – AVIATION (COST-A)
Objectives
• Mature and integrate embedded diagnostics and prognostics to decrease O&S
costs by reducing maintenance and transitioning to Condition-Based Maintenance
• Demonstrate an integrated set of prognostic technologies across six focus areas:
Propulsion, Drive, Structural, Rotor, Electrical, and Vehicle Management Systems
16
System/Sub-System-Level Reasoners Vehicle Management System (VMS)
No. 1 and No. 2 Pumps + Back-up
UH-60M VMS Components
•Multiclass SVM•Evolutionary Prog.•Particle Filter•Advanced Fusion
Health, RUL, +Conf.Vehicle
State Data
Hydraulic (Sub-) System
System Reasoning and Prognostics
Subsystem/ Component PHM
Stabilator EMA
VMS Sensor Validation & Diagnostics
Empirical System Models
Frequency Analysis
Fusion
Performance Models
Dynamic Signal Analysis
Hydraulic Pumps, Valves, Servos
VMS Sensor and Vehicle
State Data
Automatic Flight Control System
Model
System
Damage Estimator
Measured Input
Measured System Output
Output Residual + Degradation ID
-
+
+
+
Fault Effects & Variation Uncertainty
High Fidelity Dynamic Models
Current Asymmetry Analysis
0 0.01 0.02 0.03 0.04 0.05-6
-4
-2
0
2
4
6
time [sec]
curr
ent [
Am
ps]
On-Aircraft Systems Integration
Integrated Software
Aircraft Data
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© Unpublished Work, Sikorsky Aircraft (SAC) 2015. SAC Proprietary Information. All Rights Reserved. See restrictions on title page. This page contains no technical data controlled by the ITAR or EAR.
This research was partially funded by the Government under Agreement No. W911W6-10-2-0006. The U.S. Government is authorized to reproduce and distribute reprints for Government purposes notwithstanding any copyright
notation thereon. The views and conclusions contained in this document are those of the authors and should not be interpreted as representing the official policies, either expressed or implied, of the Aviation Applied Technology
Directorate or the U.S. Government.
COST-A FULL-SCALE TESTING
Point 1: 270k Cycles
Point 2: 276k Cycles
Point 3: 282k Cycles
Point 4: 291k Cycles
0 Load Block 40
Zonal PZT Damage Index Est Damage from Visual
28 Load Block 40
1
0
3.5
0
Inc
hes
296.3k 276.3k 286.3k
Zonal Direct Path Image Progression (20x30 inch area)
Top Deck Fatigue Test Article Local Eddy Current CI
17
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SHM MONITORING READINESS
18
• Individual SHM monitoring and diagnostic technologies have
matured greatly over last 10 years. Leading technologies
have achieved TRL-6+.
•Both local and zonal crack detection methods are ready for
prime time under right circumstances.
•Significant transition challenges remain:
– Lack of agreed upon reliability methods and certification
requirements
–Expense of validation and POD substantiation
–Expense of integrating into legacy aircraft and/or need for
new ground support equipment
–Scalability to total aircraft monitoring
–System productionization
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MECHANICAL DIAGNOSTICS ANALOGY
• Similarities between SHM and Mechanical Diagnostics
‒ Vibration is indirect, remote indication of gearbox faults
‒ Cost of drive system seeded fault tests are prohibitive
‒ Aircraft seeded fault tests typically not allowed
• Approach for developing condition indicators (CIs)
‒ Identify CIs via physical understanding, modeling, rig test or fleet analysis
‒ Substantiate feature performance via small-scale tests
‒ Substantiate fault progression and feature performance via full-scale tests
‒ Conduct controlled introduction to service
19
Component Tests Full-Scale System Tests Controlled Introduction to Fleet Service
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VIBRATION-BASED SHM EXAMPLES
20
Gearbox Support Crack Monitoring Tail Pylon Gearbox
Support Structure Fleet Comparison of Vibration CI
Aircraft Tail No.
Vibration HI Trend
Found Visually
Repaired
Time
Planetary Main Gearbox Carrier Plate (CP Crack Monitoring
Candidate Accel Locations
on Housing
Vibration HI Trend
GAG Cycle Number0 100 200 300 400 500 600 700 800 900 1000
Total Crack Length, inches1.3 2.5 3.0 3.5 4.1 4.5 6.8 7.1 7.6
GAG Cycle Number0 100 200 300 400 500 600 700 800 900 1000
GAG Cycle Number0 100 200 300 400 500 600 700 800 900 1000
Total Crack Length, inches1.3 2.5 3.0 3.5 4.1 4.5 6.8 7.1 7.6
Total Crack Length, inches1.3 2.5 3.0 3.5 4.1 4.5 6.8 7.1 7.6
small
crack
medium
crack
large
crack
Seeded Fault Test
Planet Assembly Carrier Plate Main Gearbox
COTS Crack Gages CP Crack Morphology
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WHAT CAN SHM COMMUNITY DO TO BE READY
TO EXPLOIT NEXT TRANSITION OPPORTUNITY? SHM Technology providers
‒ Leverage HUMS lessons learned
‒ Address technology challenges
► Develop trendable SHM CIs and robust load/temp compensation algorithms
► Develop methods for monitoring health of fail-safe SHM networks
► Develop viable approach for substantiating POD and CI performance
► Develop turnkey solutions that provides actionable info
‒ Develop list of applications for which technologies are truly transition ready
Aircraft OEMs
‒ Provide clear guidance on viable architectures and CONOPS
‒ Develop application specific approach(es) for certification
‒ Support SAE and regulatory agency efforts to develop unified guidance
HUMS OEMs
‒ Develop robust SHM interface(s) that can support multiple technologies
Regulatory Agencies and Airworthiness Authorities
‒ Support SAE efforts to develop unified guidance
‒ Solicit SHM community input into airworthiness guidelines
21
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CONCLUDING REMARKS
22
• HUMS lessons learned and infrastructure are a solid foundation for SHM
• Most likely transition opportunity is fleet issue requiring frequent inspections
during long design/dev/qual/retrofit deployment cycle
• SHM community must be positioned to respond quickly to next opportunity
• Once confidence is gained by OEM & airworthiness community, SHM will
be powerful tool for reducing operator burden while resolving fleet issues
• Close collaboration between tech developers and OEMs on specific
applications is required
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CHANGING THE O&S PARADIGM
23
Questions?