health monitoring of electrical actuators for landing gears

241 Pages·2012·4.56 MB·English

HEALTH MONITORING OF ELECTRICAL
ACTUATORS FOR LANDING GEARS
A thesis submitted to the University of Manchester for the degree of
Doctor of Engineering in the Faculty of Engineering and Physical
Science
2012
Paul Anthony Phillips
The School of Mechanical, Aerospace and Civil Engineering
TABLE OF CONTENTS
LISTOFNOTATION vii
ABSTRACT viii
DECLERATION ix
COPYRIGHT x
ACKNOWLEDGEMENTS xi
THEAUTHOR xii
CHAPTER1:INTRODUCTION 1
1.1 TheDegreeofDoctorofEngineering 1
1.2 TheSponsoringCompany 2
1.3 DivisionHistory 3
1.4 ResearchandTechnology 4
1.5 ProblemStatementandResearchMotivation 5
1.6 ResearchObjectives 8
1.7 ProjectManagement 9
1.8 ThesisLayout 9
CHAPTER2:LANDINGGEAR,ELECTROMECHANICALACTUATOR
ANDSYSTEMSBACKGROUND 12
2.1 Introduction 12
2.2 The“MoreElectricAircraft” 12
2.3 MoreElectricAircraftResearchHistory 14
2.4 CurrentRelevantEUElectricAircraftResearchprojects 17
2.4.1 CleanSkyJointTechnologyInitiative 17
HEALTHMONITORINGOFELECTRICALACTUATORSFORLANDINGGEARS
2.4.2 MoreOpenElectricalTechnologies 17
2.4.3 PowerOptimisedAircraft 17
2.4.4 ElectricLandingGearExtensionandRetraction(ELGEAR) 18
2.5 OverviewofLandingGears 18
2.6 ActuatorTypes 21
2.6.1 LeadScrew 23
2.6.2 Ballscrew 23
2.6.3 Rollerscrew 24
2.7 RegulationonLandingGearRetractionMechanisms 25
2.8 MessierDowtyActuatorDesign 27
2.9 MainRetractionActuatorControlandPerformanceRequirements 29
2.10 ReliabilityandSafetyissues 32
2.11 ActuatorComponentFailures 34
2.11.1 BearingFaults 34
2.11.2 GearFaults 35
2.11.3 RollerScrewFailure 35
2.12 Conclusion 36
2.13 References 37
CHAPTER3:CONDITIONBASEDMAINTENANCEFORENGINEERING
SYSTEMS 41
3.1 Introduction 41
3.2 FaultandFailureDefinitions 44
3.3 DiagnosticsandPrognosticDefinitions 46
3.4 ReviewofConditionBasedMaintenanceSystemRequirements 49
3.5 SystemsBasedStrategyforConditionBasedMaintenance 51
3.6 OpenSystemsArchitectureforConditionBasedMaintenance 54
3.7 SensorSystems 56
3.7.1 TechnologyAspectsofSensors 57
3.7.2 WirelessandSmartSensors 58
3.7.3 MultipleSensorNetworks 59
3.8 DataFusionOverview 60
3.8.1 FusionProcesses 62
3.8.2 DataFusionModels 63
3.8.3 ArchitectureSelection 65
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HEALTHMONITORINGOFELECTRICALACTUATORSFORLANDINGGEARS
3.8.4 TheJDLDataFusionProcessModel 65
3.9 HealthMonitoringTechniques 67
3.9.1 VibrationMonitoring 68
3.9.2 LubricantWearDebris 69
3.9.3 MotorCurrentSignatureMonitoring 70
3.9.4 ThermalMonitoring 71
3.9.5 AcousticEmissionMonitoring 71
3.9.6 PerformanceMonitoring 72
3.9.7 CorrosionMonitoring 72
3.10 CriticalReviewofMonitoringMethods 72
3.11 ExpertSystems 75
3.11.1 Model-BasedExpertSystems 75
3.11.2 KnowledgeBasedRuleSystems 77
3.11.3 NeuralNetworks 79
3.11.4 FuzzySystems 79
3.11.5 UncertaintyinExpertSystems 80
3.12 CriticalReviewofHealthMonitoringStrategies 80
3.13 Motor-DrivenActuatorHealthMonitoringReview 83
3.13.1 Overview 83
3.13.2 Aerospace 84
3.13.3 Automotive 85
3.13.4 Rail 86
3.13.5 PowerIndustry 87
3.14 Conclusion 88
3.15 References 89
CHAPTER4:UNDERSTANDINGTHECOMMERCIALBENEFITSOF
AEROSPACEHEALTHMONITORING 101
4.1 Introduction 101
4.2 CurrentAerospaceMaintenancePractice 101
4.3 ChangingMaintenancePractice 106
4.4 PredictiveMaintenance 108
4.5 ValuepotentialofPredictiveMaintenance 110
4.6 Developing,IntegratingandPricingtheTechnology 112
4.6.1 TechnicalChallengestoIntegratingHealthMonitoring 112
4.6.2 CommercialIntegrationChallenges 114
4.6.3 PricingDeploymentStrategies 116
4.7 SWOTAnalysis:ActuatorHealthMonitoringTechnology 117
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4.7.1 Strengths 118
4.7.2 Weaknesses 119
4.7.3 Opportunities 119
4.7.4 Threats 120
4.8 Conclusion 121
4.9 References 122
CHAPTER5: HEALTHMONITORINGSYSTEMSMETHODOLOGYAND
FRAMEWORK 124
5.1 Introduction 124
5.2 FrameworkObjectives 124
5.3 OverviewoftheHealthMonitoringDataFusionFramework 125
5.4 InputstotheFusionCentre 128
5.4.1 Objectives 128
5.4.2 PartTrees 130
5.4.3 FaultTrees 130
5.4.4 Observables 132
5.5 TheFusionProcess 134
5.5.1 Alignment 134
5.5.2 Association 134
5.5.3 HypothesisGeneration 136
5.5.4 HypothesisEvaluation 137
5.5.5 HypothesisSelection 138
5.6 Estimation 138
5.7 ProposedDecisionSupportOutputs 139
5.8 ConsiderationsforPracticalImplementation 139
5.8.1 Servicebayimplemented 140
5.8.2 Embeddeddeployment 141
5.9 HealthMonitoringAcceptanceCriteriaandMetrics 142
5.9.1 ValidationProcedure 142
5.9.2 FaultDiagnosticPerformanceMetrics 143
5.9.3 TechnicalValue 146
5.10 Conclusions 147
5.11 References 148
CHAPTER6:APPLICATIONOFFUZZYLOGICANDPRINCIPAL
COMPONENTANALYSISFORDETERMININGPROCESSQUALITY 150
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6.1 Introduction 150
6.2 EstimationofActuatorProcessQuality 151
6.2.1 DataRedundancy 151
6.2.2 PrincipalComponentAnalysis 152
6.2.3 ChoosingthePrincipleComponents 154
6.2.4 GeneratingPerformanceStatistics 155
6.2.5 FuzzyLogicClassification 156
6.2.6 FuzzyRuleBase 158
6.2.7 ObtainingaQuantitativeQualityIndex 160
6.3 ExperimentalDemonstration 161
6.3.1 ExperimentalObjectives 161
6.3.2 ExperimentalSetup,DataAcquisitionandPost-Processing 162
6.3.3 ImplementingaLubricationFault 164
6.3.4 ActuatorResponses 165
6.3.5 EstimatingtheNominalPCAModel 167
6.3.6 FuzzyInference 169
6.3.7 EstimationoftheActuatorQualityIndex 170
6.4 ExperimentalTestingLimitations 171
6.5 PracticalConsiderations 173
6.6 Conclusions 174
6.7 References 175
CHAPTER7:FORMULISATIONOFAPROPOSEDACTUATORHEALTH
MONITORINGALGORITHM 177
7.1 Introduction 177
7.2 FaultDiagnostics 177
7.2.1 Model-BasedFaultMonitoring 177
7.2.2 FormulatingParityRelations 178
7.2.3 DefiningResidualThresholds 180
7.2.4 TraditionalThresholdEvaluation 182
7.2.5 EvidentialReasoning 185
7.2.6 IntroducingResidualUncertainty 187
7.2.7 CombiningMultipleEvidentialIntervals 188
7.2.8 CombiningRulesforComprehensiveDiagnostics 189
7.3 AdvantagesoftheProposedMethodology 190
7.4 Conclusions 191
7.5 References 192
CHAPTER8:SYSTEMMODELLING,SIMULATIONANDDIAGNOSTICS
DEMONSTRATION 194
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8.1 Introduction 194
8.2 ModellingthelandingGearActuator 195
8.3 Simulation 197
8.3.1 OverviewoftheActuatorSIMULINKModel 197
8.3.2 ActuatorLoading 199
8.3.3 ActuatorPerformanceSimulation 200
8.4 FaultCases 202
8.5 ActuatorPerformanceAssessment 204
8.6 Parityresiduals 205
8.6.1 NominalTest 206
8.6.2 ResidualFaultSensitivity 207
8.6.3 CombiningResidualBPA's 208
8.7 DiagnosticsAlgorithmDemonstration 208
8.7.1 OverviewoftheSimulationProcess 208
8.7.2 SimulationResults 210
8.8 Conclusions 213
8.9 References 215
CHAPTER9:CONCLUSIONS 216
9.1 Summary 216
9.2 ResearchConclusions 217
9.2.1 Objective1 217
9.2.2 Objective2 218
9.2.3 Objective3 220
9.2.4 Objective4 222
9.3 ContributiontoKnowledge 223
9.4 FurtherWork 223
9.4.1 ExperimentalLandingGearTestbed 224
9.4.2 UncertaintyandPerformanceMetrics 224
9.4.3 NewSensorTechnologyandSystemsIntegration 225
9.4.4 CostModelling 225
9.4.5 RemainingLifeModels 226
9.5 PublishedResearchPapers 226
9.5.1 JournalPapers 226
9.5.2 PeerReviewedConferenceContributions 227
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LISTOFNOTATION
AE.AcousticEmissions
ANN.ArtificialNeuralNetwork
BIT.Built InTests
BPM.BasicProbabilityMass
CBM.ConditionBasedMaintenance
CEng.CharteredEngineer
CPV.CumulativePercentageVariance
ECS.EnvironmentalControlSystem
ELGEAR.ElectricLandingGearExtensionandRetraction
EMA.Electro-MechanicalActuator
ERP.EnterpriseResourcePlanning
ETA.EventTreeAnalysis
FMEA.FailureModeandEventAnalysis
FMECA.FailureModeandEventCriticalAnalysis
FTA.FaultTreeAnalysis
IET.InstituteofEngineeringandTechnology
IMechE.InstituteofMechanicalEngineering
IVHM.IntegratedVehicleHealthMonitoring
MCSA.MotorCurrentSignatureAnalysis
MEA.MoreElectricAircraft
MRO.MaintenanceRepairandOverhaul
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MRP.MaterialsResourcePlanning
O&S.OperationsandSupport
OEM.OriginalEquipmentManufacturer
PCA.PrincipleComponentAnalysis
POA.PowerOptimisedAircraft
POD.ProbabilityofDetection
POFA.ProbabilityofFalseAlarm
REACTS.ReliableElectricalActuationSystems
RTF.RuntoFailure
RUL.RemainingUsefulLife
SPE.SquaredPredictionError
SVD.SingularValueDecomposition
SWOT.Strengths,Weaknesses,OpportunitiesandThreats
TBPM.TimeBasedPreventativeMaintenance
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ABSTRACT
There are numerous benefits associated with replacing hydraulic actuators with
electrical counterparts as part of an all electric landing gear including reduced
consumption of non-propulsive engine power, reduced weight, reduced cost and the
elimination of hydraulic systems. The development of health monitoring systems to
support the introduction of electrical actuation systems into landing gears will aid in
guaranteeingreliabilityandtooptimiselandinggearmaintenanceactivities.
One of the difficulties with designing health monitoring for industrial integration
involves the large number of subject areas involved, ranging from architectural
design, software and signal processing design, hardware selection and business
modelling. The reason that many health monitoring systems never reach full
development maturity is that there is a failure in realising a holistic design process.
The purpose of this thesis and the overall contribution which has been made is to
bring together a combined understanding of landing gear design, health monitoring
and the business environment for aircraft maintenance in order for a holistic design
processforlandinggearhealthmonitoringtoberealised.
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