Structural Health Management: A Rotorcraft OEM Perspective
Structural Health Management:A Rotorcraft OEM PerspectiveMark DavisTech Fellow, Prognostics & Health ManagementSikorsky Aircraft Corporation (SAC)10th International Workshop on Structural Health MonitoringPalo Alto, CASeptember 1, 2105Export Control WarningThis document contains no technical data controlled by the ITAR or EARCopyright NoticeThis document, or an embodiment of it in any media, discloses information which is proprietary, is the property of Sikorsky Aircraft Corporation, is an unpublishedwork 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 rightis 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.
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SHM Assessment & Transition Challenges Mechanical Diagnostics Analogy Thoughts on a SHM Transition Concluding Remarks Unpublished Work, Sikorsky Aircraft (SAC) 2015. SAC Proprietary Information. All Rights Reserved. See restrictions on title page.Copyright 2015 An Unpublished work by Sikorsky Aircraft Corporation. All rights reserved (see cover page).Thispage containsno notechnicaldatacontrolledby bythetheITARor Ror EAR2
SAC HEALTH MANAGEMENT VISIONEliminate Unscheduled MaintenanceOptimize Scheduled MaintenanceFocus Troubleshooting & Reduce False RemovalsMaximize Detection Time Before FailureEnhance Safety Unpublished Work, Sikorsky Aircraft (SAC) 2015. SAC Proprietary Information. All Rights Reserved. See restrictions on title page.Copyright 2015 An Unpublished work by Sikorsky Aircraft Corporation. All rights reserved (see cover page).Thispage containsno notechnicaldatacontrolledby bythetheITARor Ror EAR3
SAC HEALTH MANAGEMENT EVOLUTIONS-76C S-92 CH-148S-61 CH-53EUH-60A,L,MSAFETYCH-53KVXXMAINTENANCE &TROUBLE SHOOTINGCONDITION BASEDMAINTENANCE Unpublished Work, Sikorsky Aircraft (SAC) 2015. SAC Proprietary Information. All Rights Reserved. See restrictions on title page.Copyright 2015 An Unpublished work by Sikorsky Aircraft Corporation. All rights reserved (see cover page).Thispage containsno notechnicaldatacontrolledby bythetheITARor Ror EAR4
SAC HEALTH MANAGEMENT SYSTEMCustomerMFDSikorskyDrivetrainDiagnosticsS-92 OperatorsWebPortalGround StationExceedanceDisplayRotor Track& BalanceHUMS CollectedDataKDTHUMS/MaintenanceData & Field EventsData TransferMultiple time a dayCI Box PlotHelicopter Flight Data Mgt.MDATMatlabProactive SupportHUMS ToolbarNew HUMSToolsPro-ActiveSupportValue: new tools, maintenance credits, etc.RetirementTimeAdjustmentS-92 Hub Unpublished Work, Sikorsky Aircraft (SAC) 2015. SAC Proprietary Information. All Rights Reserved. See restrictions on title page.Copyright 2015 An Unpublished work by Sikorsky Aircraft Corporation. All rights reserved (see cover page).Thispage containsno notechnicaldatacontrolledby bythetheITARor Ror EAR5
S-92 HUMSTen years of maturation and valueOver 250 aircraft monitoredDowntime AvoidanceExtended Time-on-WingHigh-sensitivity vibe analysisenabled early detection andproactive response.Leveraged S-92 Main Rotor Hublife adjustment to gain additionalretirement time adjustment creditsNew Detection CapabilityDecision SupportIsolated vibe-signature of previouslyundetectable pivot bearing issueand enabled software enhancementData mining and analysis tounderstand field issues andimprove decision making 750,000 Flight Hours10GB data dailyAnalysis & Tool DevelopmentWeb PortalKDTSAC GroundBased AppPart Tracker Unpublished Work, Sikorsky Aircraft (SAC) 2015. SAC Proprietary Information. All Rights Reserved. See restrictions on title page.Copyright 2015 An Unpublished work by Sikorsky Aircraft Corporation. All rights reserved (see cover page).Thispage containsno notechnicaldatacontrolledby bythetheITARor Ror EAR6
WHAT IS SHM?Common Perspective: Structural Health MonitoringTechnologies required to detect, isolate, and characterizestructural damage (e.g., cracks, corrosion, FOD, battledamage). Typically synonymous with monitoring of airframestructural damage.SAC Perspective: Structural Health ManagementHolistic cradle-to-grave approach to ensure aircraft structuralintegrity, safety, and reliability through optimized balance of design conservatism;monitoring of usage, loads, and structural damage;fleet management of flight critical componentscertification of SHM enabled condition-based maintenance (CBM). Unpublished Work, Sikorsky Aircraft (SAC) 2015. SAC Proprietary Information. All Rights Reserved. See restrictions on title page.Copyright 2015 An Unpublished work by Sikorsky Aircraft Corporation. All rights reserved (see cover page).Thispage containsno notechnicaldatacontrolledby bythetheITARor Ror EAR7
STRUCTURAL HEALTH gueTestingMaintenance Actions:Inspect, Repair, ReplacePredictive Technologies:Damage growth / RULIn-Situ Damage Detectionand Damage GrowthMonitoringNon-destructiveEvaluation and VisualInspectionsLoads, Usage,EnvironmentalOperational HistoryStructural Health ManagementFlight LoadSurvey Testing Unpublished Work, Sikorsky Aircraft (SAC) 2015. SAC Proprietary Information. All Rights Reserved. See restrictions on title page.Copyright 2015 An Unpublished work by Sikorsky Aircraft Corporation. All rights reserved (see cover page).Thispage containsno notechnicaldatacontrolledby bythetheITARor Ror EAR8
ROTORCRAFT SHM CHALLENGESVariability and Complexity of Physics of both Probabilistic & Random Failure ModesRotor HubRotor BladeBifilar AbsorberPitch HornRotor BladeCuff AssySpindle, Nut, Tie-RodFlap/Lag/Pitch/Thrust Bearing(inside hub arm)aka elastomeric/MDOF bearingSwashplate(below cowling,attaches tolower PCR end)Shaft ExtenderScissors AssyDroop StopPitchControlRodBlade PinTypical Failure Modes Fatigue FOD Corrosion BattleDamperVariability of Operational Usage & LoadsVariability of Operational & Maintenance Environments Unpublished Work, Sikorsky Aircraft (SAC) 2015. SAC Proprietary Information. All Rights Reserved. See restrictions on title page.Copyright 2015 An Unpublished work by Sikorsky Aircraft Corporation. All rights reserved (see cover page).Thispage containsno notechnicaldatacontrolledby bythetheITARor Ror EAR9
HOLISTIC SHM APPROACH Unpublished Work, Sikorsky Aircraft (SAC) 2015. SAC Proprietary Information. All Rights Reserved. See restrictions on title page.Copyright 2015 An Unpublished work by Sikorsky Aircraft Corporation. All rights reserved (see cover page).Thispage containsno notechnicaldatacontrolledby bythetheITARor Ror EAR10
USAGE/LOADS MONITORINGExample Key Physical SensorsVirtual Structural Usage/Loads Monitoring Unpublished Work, Sikorsky Aircraft (SAC) 2015. SAC Proprietary Information. All Rights Reserved. See restrictions on title page.Copyright 2015 An Unpublished work by Sikorsky Aircraft Corporation. All rights reserved (see cover page).Thispage containsno notechnicaldatacontrolledby bythetheITARor Ror EAR11
SAMPLE S-92 A/C BENEFITSLLP 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 hubsFleetmponentAnalysisrementustmentFleet Spectrum Update (Part #) Virtual Monitoring of Loads (VML) used to calculate TR torque from 500kFH HUMS data92 LoadMRstatistics used to revise usage spectrum 3.25X retirement time Same approach can be used for serial # creditHub180160Occurances140DesignA/C 11A/C 12A/C 13A/C 14A/C 15Fleet Avg1201008060Clear Ou2000-105Rotor Cycles0-110Rotor RPM Ground Air Ground CycleTBO ExtensionsTR Power (HP)40Anomaly Detectionrplot of Hours on Oil Cooler Blower at Removal DateCodeBearing F aulty or wornIndeterminateUnpublished Work, Sikorsky Aircraft (SAC)2015. SAC Proprietary Information. All Rights Reserved.Copyright 2013 An Unpublishedwork by Sikorsky Aircraft Corporation. All rights reservedInterferenceThispagecontainsno notechnicaldatacontrolledby bythetheITARor EAR.ScheduledThis documentcontainstechnicaldatacontrolledITARor EARExtension Cumulative TR Power SpectrumSee restrictions on title page.(see cover page).12
SAC SHM TECH DEVELOPMENT 010-142010-132012-172013-17RF AntennaEnergy HarvesterLoad SensorHarvester Circuit, Microprocessor,and RF Transmitter Tech Assessment Challenge ProblemCharacterization Metal sub-components& PSE Damage detectionsensing validation Load sensingevaluation Prognostic systemarchitecture VML extension Metal PSE Damage detectionsensing Damage growthmodeling Damage tolerant designframework Limited composites VML application Focus on H-60 Metals only Damage, corrosion, &impact detection andquantification VML application Addresses structures,drives, & rotors On-board/off-boardsystem integrationSIMS Structural Integrity Monitoring SystemIRDT Integrated Rotorcraft Damage ToleranceCOST-A Capability-Based Operations SustainmentTechnologies – Aviation Very focused oncomposites Local damagepropagation modeling Integration of modelswith sensor feedback Coupon testing forcorrelation with models Focus on CH-53Kcomposite aircraft Local / zonal damagemonitoring Usage & loadsmonitoring Measure load changeson select primarystructures due todamage Reduce overmaintenance ofcomposite airframes –focus on “big damage” Estimate damage fromfewer sensors Quantify effect ofdamage on loaddistribution and DT Multi-site DamageRDDT Rotorcraft Durability and Damage ToleranceIHSMS Integrated Hybrid Structural Management SystemASTRO Autonomous Sustainment Technologies for RotorcraftOperations Unpublished Work, Sikorsky Aircraft (SAC) 2015. SAC Proprietary Information. All Rights Reserved. See restrictions on title page.Copyright 2015 An Unpublished work by Sikorsky Aircraft Corporation. All rights reserved (see cover page).Thispage containsno notechnicaldatacontrolledby bythetheITARor Ror EAR13
TECHNOLOGY READINESS DEFINITIONSIn 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 Bulk ofPrincipleswork in SHMcommunity TRL 3 to 6Ok for R&D and at-aircraft monitoringTRL-7 required for embedded systemsTRL-8 required for CBM creditsTRL 9---TRL 8---TRL 7---TRL 6---TRL 5---TRL 4---TRL 3---TRL 2---TRL 1 System Completed Flt / Mission Qual System/SubsystemDevelopment Tech Demo Tech Development Research to ProveFeasibility Basic Research Unpublished Work, Sikorsky Aircraft (SAC) 2015. SAC Proprietary Information. All Rights Reserved. See restrictions on title page.Copyright 2015 An Unpublished work by Sikorsky Aircraft Corporation. All rights reserved (see cover page).Thispage containsno notechnicaldatacontrolledby bythetheITARor Ror EAR14
SAC SHM TRL PROGRESSIONSub-Component RRSub-Component (TRL 3-5)(Doubler Joint) RepresentativeFeatures Lab transducers, DAQ,and processorsLaserScribeDoubler JointAngle Lap Joint50-100 tests*Stiffened Bay Panels20-30 tests*Full-Scale Primary Structural Elements (PSEs) & Sub-Assemblies (TRL 5-6) Full-Scale test articles Representative SHMhardware/software Software partiallyintegrated withOBS/GBS HUMS/IVHMSBeam/Frame JointFrame Splice1-5 tests** Rough number ofthat can beCabin Top-Deck Sub-Assembly testsconducted for cost ofone sub-assembly test1 test* Unpublished Work, Sikorsky Aircraft (SAC) 2015. SAC Proprietary Information. All Rights Reserved. See restrictions on title page.Copyright 2015 An Unpublished work by Sikorsky Aircraft Corporation. All rights reserved (see cover page).Thispage containsno notechnicaldatacontrolledby bythetheITARor Ror EAR15
CAPABILITY-BASED OPERATION SUSTAINMENTTECHNOLOGY – AVIATION (COST-A)Objectives Mature and integrate embedded diagnostics and prognostics to decrease O&Scosts 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 SystemsSystem/Sub-System-LevelReasonersVehicle Management System (VMS)On-Aircraft Systems IntegrationSystem Reasoning and PrognosticsVehicleState Data Multiclass SVM Evolutionary Prog. Particle Filter Advanced FusionHealth,RUL, Conf.FusionSubsystem/ Component PHMHydraulic (Sub-) SystemEmpiricalSystemModelsDynamic SignalAnalysisFrequencyPerformanceModelsNo. 1 andAnalysisNo. 2Pumps Back-upAutomatic Flight Control SystemHigh Fidelity DynamicModelsFault Effects &Variation Uncertainty SystemMeasuredInputMeasured SystemOutputIntegrated Software Output Residual Degradation IDModel Hydraulic Pumps,Valves, ServosDamage Estimator64CurrentAsymmetry Analysiscurrent [Amps]VMS Sensor Validation& Diagnostics20-2-4-600.010.020.03time [sec]0.040.05UH-60M VMSComponentsVMS Sensorand VehicleState DataStabilator EMAAircraft Data 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 purposesnotwithstanding 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,Copyright 2015An Unpublishedworkby SikorskyAircraft Corporation. All rights reserved (see cover page).16either expressed or implied, of the AviationAppliedTechnologyDirectorate orthe U.S.Government.This document contains no technical data controlled by the ITAR or EAR
COST-A FULL-SCALE TESTINGLocal Eddy Current CITop Deck Fatigue Test ArticlePoint 1: 270k CyclesPoint 2: 276k CyclesPoint 3: 282k CyclesPoint 4: 291k CyclesZonal Direct Path Image Progression (20x30 inch area)276.3kZonal PZT Damage Index3.5296.3kEst Damage from VisualInches1286.3k00Load Block40028Load Block40 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 copyrightnotation thereon. The views and conclusionscontained in 2013this documentare those of theauthorsand should Aircraftnot be interpretedas representingthe officialpolicies,eitherexpressedor implied, of the Aviation Applied TechnologyCopyrightAn Unpublishedworkby SikorskyCorporation.All rightsreserved(seecoverpage).Directorate or the U.S. Government.17This document contains no technical data controlled by the ITAR or EAR
SHM MONITORING READINESS Individual SHM monitoring and diagnostic technologies havematured greatly over last 10 years. Leading technologieshave achieved TRL-6 . Both local and zonal crack detection methods are ready forprime time under right circumstances. Significant transition challenges remain:– Lack of agreed upon reliability methods and certificationrequirements– Expense of validation and POD substantiation– Expense of integrating into legacy aircraft and/or need fornew ground support equipment– Scalability to total aircraft monitoring– System productionization Unpublished Work, Sikorsky Aircraft (SAC) 2015. SAC Proprietary Information. All Rights Reserved. See restrictions on title page.Copyright 2015 An Unpublished work by Sikorsky Aircraft Corporation. All rights reserved (see cover page).Thispage containsno notechnicaldatacontrolledby bythetheITARor Ror EAR18
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 serviceComponent TestsFull-Scale System TestsControlled Introduction to Fleet Service Unpublished Work, Sikorsky Aircraft (SAC) 2015. SAC Proprietary Information. All Rights Reserved. See restrictions on title page.Copyright 2015 An Unpublished work by Sikorsky Aircraft Corporation. All rights reserved (see cover page).Thispage containsno notechnicaldatacontrolledby bythetheITARor Ror EAR19
VIBRATION-BASED SHM EXAMPLESGearbox Support Crack MonitoringTail Pylon GearboxSupport StructureVibration HI TrendFleet Comparison of Vibration CIFound VisuallyRepairedTimeAircraft Tail No.Planetary Main Gearbox Carrier Plate (CP Crack MonitoringMain Gearbox Planet AssemblyVibration HI TrendCarrier PlateSeeded Fault TestsmallcrackCOTS Crack GagesCP Crack MorphologymediumcracklargecrackCandidate Accel Locationson Housing0100200300400500600Cycle Number Unpublished Work, Sikorsky Aircraft (SAC) 2015. SAC Proprietary Information. All Rights Reserved.1.3 ight 2015 An Unpublished work by Sikorsky Aircraft Corporation. All rights reserved (see cover page).Total Crack Length, heITARorEAR.This document contains no technical data controlled by the ITAR or EAR7008006.89007.110007.620
WHAT CAN SHM COMMUNITY DO TO BE READYTO 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 readyAircraft 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 guidanceHUMS OEMs‒ Develop robust SHM interface(s) that can support multiple technologiesRegulatory Agencies and Airworthiness Authorities‒ Support SAE efforts to develop unified guidance‒ Solicit SHM community input into airworthiness guidelines Unpublished Work, Sikorsky Aircraft (SAC) 2015. SAC Proprietary Information. All Rights Reserved. See restrictions on title page.Copyright 2015 An Unpublished work by Sikorsky Aircraft Corporation. All rights reserved (see cover page).Thispage containsno notechnicaldatacontrolledby bythetheITARor Ror EAR21
CONCLUDING REMARKS HUMS lessons learned and infrastructure are a solid foundation for SHM Most likely transition opportunity is fleet issue requiring frequent inspectionsduring 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 willbe powerful tool for reducing operator burden while resolving fleet issues Close collaboration between tech developers and OEMs on specificapplications is required Unpublished Work, Sikorsky Aircraft (SAC) 2015. SAC Proprietary Information. All Rights Reserved. See restrictions on title page.Copyright 2015 An Unpublished work by Sikorsky Aircraft Corporation. All rights reserved (see cover page).Thispage containsno notechnicaldatacontrolledby bythetheITARor Ror EAR22
CHANGING THE O&S PARADIGMQuestions? Unpublished Work, Sikorsky Aircraft (SAC) 2015. SAC Proprietary Information. All Rights Reserved. See restrictions on title page.Copyright 2015 An Unpublished work by Sikorsky Aircraft Corporation. All rights reserved (see cover page).Thispage containsno notechnicaldatacontrolledby bythetheITARor Ror EAR23
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
EUROCOPTER FRANCE MODELS AS350B, AS350B1, AS350BA, AS350B2 and AS350B3 ROTORCRAFT FLIGHT MANUAL WITH THE INLET BARRIER FILTER SYSTEM INSTALLATION Aircraft S/N_ Aircraft Reg. No. _ This supplement must be attached to applicable FAA Approved Rotorcraft Flight Manual, when the rotorcraft is modified by the installation of the DCI Inlet Barrier Filter (IBF) System in accordance with STC No .
σ rotor solidity, (blade area)/A Ω rotor rotational speed Introduction CAMRAD II is an aeromechanical analysis of helicopters and rotorcraft that incorporates a combination of advanced technology, including multibody dynamics, nonlinear finite elements, and rotorcraft aerodynamics. For the design, testing, and evaluation of rotors and rotorcraft;Cited by: 238Publish Year: 1998Author: Wayne Johnson, Johnson Aeronautics
future holds great potential if critical fundamental and advanced technology is aggressively pursued. Both the current immaturity and the future potential of rotorcraft technology stem from the same key factor - the fundamental complexity of rotorcraft aerophysics. In years past, the difficulties presented by these complex problems afforded .
2.1 Structural Health Monitoring Structural health monitoring is at the forefront of structural and materials research. Structural health monitoring systems enable inspectors and engineers to gather material data of structures and structural elements used for analysis. Ultrasonics can be applied to structural monitoring programs to obtain such .
AIM Airman’s Information Manual . AIRMETS Airman’s Meteorological Information . ATC Air Traffic Control . CFIT Controlled Flight into Terrain . CRM Crew Resource Management . FAA Federal Aviation Administration . test. FAA-S-8081-7B. 1. 7 . 2. 3 . Flight Instructor Rotorcraft – Helicopter .
These mechanics may be modeled as elastic couplings between the aircraft and the ground, represented by a 6-DOF spring in R 3 SO (3) . We show that Proportional Derivative attitude and position controllers that stabilize a rotorcraft in free ight will also stabilize the aircraft during contact for a range of contact displacements and stiffnesses.
maneuver load factor approach was better for real-time simulation, i.e., produced greater fidelity, as compared to the control stick positions approach. Thus, neural networks show promise for use in high-fidelity, real-time modeling of rotorcraft vibration. Introduction In order to expedite pilot training, it is important for
and confirm that they have no conflict before accepting the appointment. External examiners must advise the Quality & Academic Standards Office immediately via email at pgtexamining@lshtm.ac.uk if a declaration of a conflict of interest needs to be made before appointment or arises during their term. 1. The LSHTM will not appoint anyone in the following categories or circumstances as an .
