Sikorsky'S Health Management Journey: Past, Present And Future

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Airworthiness, CBM and HUMS Specialists’ MeetingHuntsville, Alabama / February 9-11, 2015SIKORSKY’S HEALTH MANAGEMENTJOURNEY: PAST, PRESENT AND FUTUREJames P. CyconManager, Health Management SystemsSikorsky Aircraft CorporationExport WarningThis document contains no technical data controlled by EAR or ITAR.Proprietary Information NoticeThis document, or an embodiment of it in any media, discloses information which is proprietary, is the property of Sikorsky Aircraft Corporation, is an unpublished workprotected under applicable copyright laws, and is delivered on the express condition that it is not to be used, disclosed, or reproduced, in whole or in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 (includingreproduction 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 todisclose or so use any information contained therein. All rights reserved. Any act in violation of applicable law may result in civil and criminal penalties.This page contains no technical data controlled by the ITAR or EAR. Unpublished Work, Sikorsky Aircraft Corporation (SAC) 2015. All Rights Reserved.See restrictions on title page.

SAC HEALTH MANAGEMENT EVOLUTIONS-76C S-92A CH-148S-6 S-76D CH-53EUH-60A,L,MCH-53 HLRSAFETYMH-60S/RMAINTENANCE &TROUBLE SHOOTINGCONDITION BASEDMAINTENANCEThis page contains no technical data controlled by the ITAR or EAR. Unpublished Work, Sikorsky Aircraft Corporation (SAC) 2015. All Rights Reserved.See restrictions on title page.2

SAC HEALTH MANAGEMENT VISIONEliminate Unscheduled MaintenanceOptimize Scheduled MaintenanceFocus Troubleshooting & Reduce False RemovalsMaximize Detection Time Before FailureEnhance SafetyThis page contains no technical data controlled by the ITAR or EAR. Unpublished Work, Sikorsky Aircraft Corporation (SAC) 2015. All Rights Reserved.See restrictions on title page.3

S-92 HEALTH MANAGEMENT SYSTEMCustomerSikorskyMFDGround BasedApplicationKDTHUMS/MaintenanceData & Field EventsS-92 Operators“Check HUMS”HUMSCollectedDataWeb PortalHelicopter Flight Data Mgt.Data TransferMultiple time a dayProactive SupportCI Box PlotSPLATMatlabNew HUMS ToolsVALUE TO THE OPERATORNew HUMS tools, maintenance credits, etc.RetirementTimeAdjustmentS-92 HubThis page contains no technical data controlled by the ITAR or EAR. Unpublished Work, Sikorsky Aircraft Corporation (SAC) 2015. All Rights Reserved.See restrictions on title page.4

S-92 TEN YEARS OF MATURATIONS-92 FMOCNow 250 aircraftDowntime AvoidanceExtended Time-on-WingHigh-sensitivity vibe analysis enabledearly detection of degrading health andproactive response.Leveraged S-92 Main Rotor Hub lifeadjustment to gain additional retirementtime adjustment credits from the FAANew Detection CapabilityLevel-of-Repair OptimizationResearch isolated vibe-signature ofpreviously undetectable Pivot Bearingissue and enabled software enhancementIdentified opportunity to significantlyreduce removals of APU Generator - atop AOG driver650 GAGs*Base ofCenterPost120% TpOuterPlateEdge10GB data dailyThis page contains no technical data controlled by the ITAR or EAR. Unpublished Work, Sikorsky Aircraft Corporation (SAC) 2015. All Rights Reserved.See restrictions on title page.5

260 HoursEXTENDING TIME-ON-WINGLLP Retirement Extension (Serial #)ersFAA approved S-92 main rotor (MR) hub lifeFleetComponentAverage benefit of 50% one-time CRTextensionAnalysRetirementAdjustmentFleet SpectrumUpdate (Part #)Virtual Monitoring of Loads (VML) used to calculate TR torque from 500kFHS-92 MRLoad statistics used to revise usage spectrum 3.25X retirement timeHub 180gOccurances140DesignA/C 11A/C 12A/C 13A/C 14A/C 15Fleet Avg1201008060200TR Power (HP)400-105Rotor Cycles0-110Rotor RPM Ground Air Ground CycleTBO ExtensionsAnoScatterplot of Hours on Oil Cooler Blower at Removal DateCumulativeTR Power Spectrum3500ExtensionCode3000ovalRPM1602500 TBOBearing F aulty or wornIndeterminateThis page contains no technical data controlled by the ITAR or EAR.InterferenceScheduledUnpublished Work, Sikorsky Aircraft Corporation (SAC) 2015. All RightsReserved.VibrationsLevelSee restrictions on title page.62 Limit 0.45 G

“BIG DATA” ANALYTICS APPLICATIONSHadoop Cluster The new paradigm – cloud computingHADOOP by ClouderaAnalysis acrossthe entirefleet (16 Tb)in a fewminutes.Tail analysisCustom queriesacross fleet-wideparametric data HADOOP An open source implementation ofMapReduce, a powerful for deep analysis ofvery large data sets.This page contains no technical data controlled by the ITAR or EAR. Unpublished Work, Sikorsky Aircraft Corporation (SAC) 2015. All Rights Reserved.See restrictions on title page.7

EXPANDING ANALYTICSOptimizing support through awareness and insightFleet DemographicsHealth Monitoring and Drill-DownSupply Chain OptimizationText mining and StatisticalAnalysisCost/MaintenanceTrending and InvestigationMaintenance OptimizationThis page contains no technical data controlled by the ITAR or EAR. Unpublished Work, Sikorsky Aircraft Corporation (SAC) 2015. All Rights Reserved.See restrictions on title page.8

PHM SYSTEM INTEGRATION LAB (SIL)Architectural Elements Developed in Parallel to Subsystem Technology MaturationThis page contains no technical data controlled by the ITAR or EAR. Unpublished Work, Sikorsky Aircraft Corporation (SAC) 2015. All Rights Reserved.See restrictions on title page.9

SIL PLAYBACK SYSTEMEnabling capability for PHM Development and TestingPrimary FunctionalityOther Aircraft SIL(s)Ground Test Stand(s)Playback System Seamlessly merge integratedflight data, seeded fault data,simulated data Playbackdatatofullysimulate avionics systemSimulation Offline ElementRecorded DataPHM SILMan Machine InterfaceChallenges Specifying and developingintuitive user interface Converting often massive,heterogeneous data files tocommon format Defining and implementingplayback interfacesSikorskyLocal el)PHM SILLiveTestStandsSystem Under TestThis page contains no technical data controlled by the ITAR or EAR. Unpublished Work, Sikorsky Aircraft Corporation (SAC) 2015. All Rights Reserved.See restrictions on title page.10

REAL-TIME DATA DOWNLOADInternetSatellite Message Small Offload ( 10Kbytes) Push Only 2.4Kbits/sFlight Operations CenterCellular Message Partial On-Demand Offload ( 1MByte) Push/Pull Ground can request additional data 300KBits/s (3G) Immediate access to dataShortened post flightprocessAutomated post flightprocessStandard communicationprotocolsTabletAt WingWi-Fi Message Full Offload of MUD File Up to 256MBytes 54MBits/s timely access to informationThis page contains no technical data controlled by the ITAR or EAR. Unpublished Work, Sikorsky Aircraft Corporation (SAC) 2015. All Rights Reserved.See restrictions on title page.11

MOBILE MX TOOLKIT WORKFLOWFleet ViewTail SummaryDrilldownWirelessTransmissionThis page contains no technical data controlled by the ITAR or EAR. Unpublished Work, Sikorsky Aircraft Corporation (SAC) 2015. All Rights Reserved.See restrictions on title page.12

SAC GROUND BASED APPLICATIONSikorsky SGBA Key FunctionsOperation UsageMechanical DiagnosticsRTBFlight Manual ExceedancesAlert TrendingParametricHUMS ToolbarThis page contains no technical data controlled by the ITAR or EAR. Unpublished Work, Sikorsky Aircraft Corporation (SAC) 2015. All Rights Reserved.See restrictions on title page.13

INCREASING THE VALUE OF HUMSTransition to CBM Expand Safety AttributesIncorporate intoAircraft DeliveryProcessChange the Design ParadigmThis page contains no technical data controlled by the ITAR or EAR. Unpublished Work, Sikorsky Aircraft Corporation (SAC) 2015. All Rights Reserved.See restrictions on title page.14

Questions?Questions?This page contains no technical data controlled by the ITAR or EAR. Unpublished Work, Sikorsky Aircraft Corporation (SAC) 2015. All Rights Reserved.See restrictions on title page.15

Sikorsky Aircraft Corporation Export Warning This document contains no technical data controlled by EAR or ITAR. Proprietary Information 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

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