Date post: | 15-Jan-2016 |
Category: |
Documents |
Upload: | horatio-shepherd |
View: | 223 times |
Download: | 2 times |
Boeing Defense, Space & Security
PhantomWorks
Copyright © 2014 Boeing. All rights reserved.
OSST-II OverviewPresenter: Doug Knapp
1
Society of Reliability Engineers (SRE) Huntsville Chapter, RAM VII Workshop
04 Nov 2014Distribution Statement A: Approved for public release; distribution is unlimited.
This research was partially funded by the Government under Agreement No. W911W6-11-2-0003. The U.S. Government is authorized to reproduce and distribute reprints for Government purposes notwithstanding any copyright notation thereon.
Copyright © 2014 Boeing. All rights reserved.
BDS | PhantomWorks
Distribution Statement A: Approved for public release; distribution is unlimited.
Operations Support and Sustainment Technologies Phase II (OSST-II)
Background: Army desires to transition aviation fleet to Condition Based Maintenance (CBM)
Purpose: Technology development and demonstration to TRL4 (component and/or breadboard validation in laboratory environment)
Objectives: Continue development and demonstrate 2016 Army S&T O&S metrics
Scope: Electrical Project Propulsion Project VMS Project (Vehicle Management System)
2
Copyright © 2014 Boeing. All rights reserved.
BDS | PhantomWorks
Distribution Statement A: Approved for public release; distribution is unlimited.
CBM Program Objectives and Key Enablers
OSST-II Program supports Army CBM Program
3
Courtesy U.S. Army
Copyright © 2014 Boeing. All rights reserved.
BDS | PhantomWorks
Distribution Statement A: Approved for public release; distribution is unlimited.
Metrics
Predicted contributions to 2016 Metric Goals
4
2016 S&T O&S Metric Goals(2005 Fielded Aircraft Baseline) (P
) Pro
pu
lsio
n
(E) E
lect
rica
l
(V) V
MS
65% Reduction in Inspections/Flight Hourhigh low high
15% Reduction in Maintenance Labor/Flight Hourmedium medium medium
20% Increase Component Mean Time Between Removals medium medium medium
Less than 3% False Removal Rateshigh high high
25 Hour Detection Time Before Failurehigh high high
10% Reduction in System and Installation Costmedium medium high
10% Reduction in System Weightmedium medium nil
high (>50%)medium (20-50%)low (<20%)nil (no contribution, or negative contribution)
Contribution to 2016 Metric Goals (%)
Copyright © 2014 Boeing. All rights reserved.
BDS | PhantomWorks
Distribution Statement A: Approved for public release; distribution is unlimited.
Transition (2011 Outlook)
5
Technology demo
Boeing product capability
Rotorcraft platforms
Courtesy U.S. Army, AATD 2011
Copyright © 2014 Boeing. All rights reserved.
BDS | PhantomWorks
Distribution Statement A: Approved for public release; distribution is unlimited.
Transition Lookahead
6
Copyright © 2014 Boeing. All rights reserved.
BDS | PhantomWorks
Distribution Statement A: Approved for public release; distribution is unlimited.
Electrical System ‒ Vision
Leverage the ubiquitous nature of the electrical system to create a CBM communications infrastructure to enable low cost, minimally intrusive and pervasive health management (HM) for the vehicle.
Make the CBM infrastructure open and easy to use to provide the flexibility and adaptability required for growth.
Develop CBM applications for selected subsystems based on their inherent benefit and to demonstrate the utility of the infrastructure.
7
Copyright © 2014 Boeing. All rights reserved.
BDS | PhantomWorks
Distribution Statement A: Approved for public release; distribution is unlimited.
Electrical System ‒ Tech Approach
Electronic circuit breakers (ECBs) in a solid state power distribution system (PDS) is leveraged to
monitor electrical loads.Ultra Wideband over Wire (Ultra WoW) to implement a virtual bus to communicate CBM data from line
replaceable units (LRUs) that have a bus interface (e.g., Mil-Std-1553).
Power line communications (PLC) to move data from LRUs or major components that do not support a
bus interface.CBM system built upon an open, partitioned, plug and play software infrastructure
to reduce development and integration costs, and provide a platform for future growth.
8
Copyright © 2014 Boeing. All rights reserved.
BDS | PhantomWorks
Distribution Statement A: Approved for public release; distribution is unlimited.
Electrical System ‒ Apache Applications
Three (3) CBM Demonstration ThreadsGenerator Electrical generator bearing
Blower ECS (Environmental Control System) Blower motor bearing and
foreign object damage (FOD)Electronics Power supply and inverter Distance to fault for wiring
9
Copyright © 2014 Boeing. All rights reserved.
BDS | PhantomWorks
Distribution Statement A: Approved for public release; distribution is unlimited.
Electrical System Project Plan
Industry Partners; Leverage SBIR, IRAD funded technologies
10
Copyright © 2014 Boeing. All rights reserved.
BDS | PhantomWorks
Distribution Statement A: Approved for public release; distribution is unlimited.
Electrical System Demonstration
Demonstration Threads
11
Copyright © 2014 Boeing. All rights reserved.
BDS | PhantomWorks
Distribution Statement A: Approved for public release; distribution is unlimited.
Electrical System Demonstration
Boeing test standAircraft equipment
12
AC and DC Load Banks
Generator Drive Stand
Aircraft Equipment Rack
Test Bench Operator’s Station
Bearing Cage front half
Rivet
Driveshaft
Copyright © 2014 Boeing. All rights reserved.
BDS | PhantomWorks
Distribution Statement A: Approved for public release; distribution is unlimited.
Electrical Power Demonstration System
Demonstration Threads
13
CBM Application
Enabling Technology
Generator Bearing
Blower Motor Bearing
Power Supply and Inverter
Distance to Fault
PDS as a Sensor Monitor motor current for health indicator.
Provide data to distinguish arcing from load characteristics. Potential to host DTF electronics.
Ultra WoW Communicated sensor/processed data for health indicator.
Powerline Communications
Communicated sensor data over main power feeder.
Communicated sensor data over existing power wire.
CBM System Common open, partitioned, Plug and play infrastructure.
Common open, partitioned, Plug and play infrastructure.
Common open, partitioned, Plug and play infrastructure.
Common open, partitioned, Plug and play infrastructure.
Copyright © 2014 Boeing. All rights reserved.
BDS | PhantomWorks
Distribution Statement A: Approved for public release; distribution is unlimited.
Propulsion Project (Approach & Benefits)
14
Develop sensor platform to measure multiple oil & component parameters.
Integrate COTS sensor technology.
Utilize wireless communications.Develop prognostics through
embedded algorithms using dynamic model of components and fluid conduits.
Bench test Advanced Sensor Platform.
Demonstrate with MELB Engine and Transmission.
OSST II Propulsion Design Targets2013 Technology Goals and 2016 S&T O&S Metrics
Copyright © 2014 Boeing. All rights reserved.
BDS | PhantomWorks
Distribution Statement A: Approved for public release; distribution is unlimited.
Propulsion Project Plan
Industry Partners; Leverage SBIR, IRAD funded technologies
15
Copyright © 2014 Boeing. All rights reserved.
BDS | PhantomWorks
Distribution Statement A: Approved for public release; distribution is unlimited.
Sensor Parameters
16
*O=Oil Aging/Contamination, W=Water Contamination, B=Bearing/Gear Fatigue, G=Gear Pump Degradation, F=Filter Loading, P=Pressure Regulation, C=Cooler Performance, L=Line Restriction
Copyright © 2014 Boeing. All rights reserved.
BDS | PhantomWorks
Distribution Statement A: Approved for public release; distribution is unlimited.
Mapping System Features to Metrics
17
Lubricant degradation, RUL
Lubricant contamination
Bearing/gear fatigue
Lube pumpperformance, RUL
Lube / scavenge filter loading, RUL
Cooler performance
Sensor built-in-test, self-accommodation
Specific BenefitSystem Feature OSST Impact
Reduce inspection 65% per flight hour
Related Metrics
Multiparametric oil properties
Critical oil debris
Flow rate, RPM supply pressure
Oil temperature
Algorithms providing:Signal processing,Self-diagnostics,
data fusion, physical/empirical models
Integrated nodes,Wireless hub
15% reduction in labor
20% MTBR increase
< 3% False removals
> 25 hr detection time before failure
10% reduction in installation cost
10% reduction in system weight
Extended oil intervals
Reduced oil inspections
Earlier bearing/gear fault indication with less false-positives
Localize pump faults,Improved maintenance
scheduling
Reduced weight, integration effort
Increased filter life utilization, improved maint. scheduling
Localize cooler / bypass valve faults
Localize sensor faults
Reduced weight, integration effort
Copyright © 2014 Boeing. All rights reserved.
BDS | PhantomWorks
Distribution Statement A: Approved for public release; distribution is unlimited.
Test Plan Overview (MELB Transmission)
18
Test 1 – Initial Checkout and AcceptanceTest 2 – Baseline ConditionTest 3 – Fault Condition A: Water ContaminationTest 4 – Fault Condition B: Bearing Debris, Static FlowTest 5 – Fault Condition C: Bearing Debris, Dynamic FlowTest 6 – Fault Condition D: Silica Dust, Dynamic FlowTest 7 – Fault Condition E: Gear Pump WearTest 8 – Fault Condition F: Incorrect Lubricant Contamination
Copyright © 2014 Boeing. All rights reserved.
BDS | PhantomWorks
Distribution Statement A: Approved for public release; distribution is unlimited.
RR250-C30P Engine Demo
19
Supply-side Sensor Node
Scavenge-side Sensor Node
Supply Pump Pressure Sensor
From Engine
To ScavFilter
RR 250-C30Test Article
HM System
Master Hub Enclosure
Sensor, Power, Comm Connections
Mounting Plate
Debris Chamber
Hardware installed on RR250-C30 Sensor nodes plumbed into flex lines Master hub mounting arrangement Injector port for dirt and steel chips
Copyright © 2014 Boeing. All rights reserved.
BDS | PhantomWorks
Distribution Statement A: Approved for public release; distribution is unlimited.
MELB Main Transmission Demo
Hardware installed via plumb lines, master hub, injector port
20
C
B
A
(A) MELB Transmission (retired on flight hours) (B) OSST-II hardware installation, showing master hub unit(C) OSST-II hardware installation, showing sensors and fluid connections
Copyright © 2014 Boeing. All rights reserved.
BDS | PhantomWorks
Distribution Statement A: Approved for public release; distribution is unlimited.
MELB Main Transmission Demo
Hardware installed via plumb lines, master hub, injector port
21
(A) OSST-II hardware installed in the vicinity of the slave gearbox unit.
(B) Clearance measurement near pump inlet/outlet ports. (C) Fluid aeration within the gearbox sump while stopped.
Copyright © 2014 Boeing. All rights reserved.
BDS | PhantomWorks
Distribution Statement A: Approved for public release; distribution is unlimited.
VMS Project (Approach & Benefits)
22
OSST II VMS Design Targets 2013 Technology Goals and 2016 S&T O&S Metrics
OSST VMS Design• Selection of Higher Payoff CBM
Applications• Analysis of No Fault Founds,
Intermittents and Extended Troubleshooting
• Data Mining• Performance Analysis of Actuators• Development of Health Indicators
for Electro-mechanical and Hydraulic Actuator
• Fault Patterns in Reasoner• Vehicle Level Integration• System Demonstration in Test
Facilities
ERDS
Block-III
V-22
S-100A H-64
A160
CH-47 Boeing Programs:
CRADIRAD
Vehicle Field Data
Emerging AED Findings
RAM DRIVERS
CAPTURE
& ADAPT
LEVERAGE
2016 S&T O&S Metric Goals(2005 Fielded Aircraft Baseline) (P
) Pro
puls
ion
(E) E
lect
rical
(V) V
MS
65% Reduction in Inspections/Flight Hourhigh low high
15% Reduction in Maintenance Labor/Flight Hourmedium medium medium
20% Increase Component Mean Time Between Removals medium medium medium
Less than 3% False Removal Rateshigh high high
25 Hour Detection Time Before Failurehigh high high
10% Reduction in System and Installation Costmedium medium high
10% Reduction in System Weightmedium medium nil
high (>50%)medium (20-50%)low (<20%)nil (no contribution, or negative contribution)
Contribution to 2016 Metric Goals (%)
Copyright © 2014 Boeing. All rights reserved.
BDS | PhantomWorks
Distribution Statement A: Approved for public release; distribution is unlimited.
VMS Project Plan
Industry Partners; Leverage SBIR, IRAD funded technologies
23
Copyright © 2014 Boeing. All rights reserved.
BDS | PhantomWorks
Distribution Statement A: Approved for public release; distribution is unlimited.
VMS Focus Areas (application categories)
24
Health Management & Analysis
Focus on No Fault Found (NFF) and maintenance event records
Utilized academia (Univ Tennessee, Vanderbilt Univ)
Yield relevant technology maturation for future development
est. <TRL4 for Apache application
Actuator Rigging
est. TRL4 auto rigging to reduce O&S burden
Actuator Prognostics
est. TRL4 diagnostics/prognostics for stabilator actuator degradation
Copyright © 2014 Boeing. All rights reserved.
BDS | PhantomWorks
Distribution Statement A: Approved for public release; distribution is unlimited.
Actuator Prognostics Overview
25
Early Program Effort Correlating Existing MDR and Unit Leven Logistics System Aviation (ULLSA) Data
Actuator Life on Wing Distribution (many early removals indicates shot gun maintenance)
Correlation of Fault Codes to Removals (weak correlation, no forensics)
Estimating NFF Rate (extremely high)
Characterizing Degrading ActuatorsFinal objective and focus of 2013-2014 testing and analysis effort
TRL4 prognostics may reduce instances of early removals and NFFs
These “new technology” efforts concluded in 2012
Copyright © 2014 Boeing. All rights reserved.
BDS | PhantomWorks
Distribution Statement A: Approved for public release; distribution is unlimited.
Actuator Prognostics Overview
26
Final Objective — to use the rates as a measurement of degradation in the stabilator actuator, also known as Electro-Mechanical Actuator (EMA)
Approach By comparing the actuator commands and responses during the preflight IBIT test
portion for the flight data that is available, determine whether or not there are observable degradations over time
Assuming that there are observable degradations over time, incorporate this information into a failure prediction model
Develop an automated script to compare the command versus the response and look at the margins in the test
Data was convincing as useful for performance evaluation
Copyright © 2014 Boeing. All rights reserved.
BDS | PhantomWorks
Distribution Statement A: Approved for public release; distribution is unlimited.
Actuator Prognostics Overview
Stabilator Actuator on aircraft
27
Copyright © 2014 Boeing. All rights reserved.
BDS | PhantomWorks
Distribution Statement A: Approved for public release; distribution is unlimited.
Actuator Prognostics Overview
Stabilator Actuator components susceptible to wear Motor commutation Brushes DC motor bearings Gear train wear Gear train bearings Limit switch failure.
Fault Modes Typically slow degradation in
actuator drive rate with (brush/bearing) wear out.
Increasingly large variance in drive rate with wear out.
28
2 back-to-back Stabilator Actuators
Copyright © 2014 Boeing. All rights reserved.
BDS | PhantomWorks
Distribution Statement A: Approved for public release; distribution is unlimited.
Actuator Prognostics Overview
Stabilator Actuator in lab (bench test, tear down)
29
Copyright © 2014 Boeing. All rights reserved.
BDS | PhantomWorks
Distribution Statement A: Approved for public release; distribution is unlimited.
Acknowledgements
AATD Leadership: Mr. Ming Lau, Power Systems DivisionOSST II Program – AATD Team: Program Manager, Treven Baker Technical / Program Agent, Christopher Lyman Contracts, Kenneth Helms and Robert Waible
Disclaimer:
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.
30
Copyright © 2014 Boeing. All rights reserved. 31