Industry Canada Aircraft Systems Diagnostics Prognostics and Health Management Technology Insight Document

81 Pages·0.671 MB·English

Aircraft Systems
Diagnostics, Prognostics and Health Management
Technology Insight Document

Industry Canada Contract 5011101
Version: 0.2 (DRAFT)
Date: 16 December 2004
Aircraft Systems Diagnostics Prognostics and Health Management
Technology Insight Document
Industry Canada Version 0.2 – 16 Dec 04
Table of Contents
Table of Contents...............................................................................................................i
1 Introduction................................................................................................................1
1.1 Background.......................................................................................................1
1.2 Aircraft Diagnostics, Prognostics and Health Management..............................1
1.3 Aircraft Sub-systems.........................................................................................2
1.3.1 Aero-propulsion Systems..............................................................................2
1.3.2 Aircraft Structures..........................................................................................2
1.3.3 Ancillary Systems..........................................................................................2
1.3.4 DPHM Systems Integration...........................................................................3
1.4 Vision.................................................................................................................3
1.5 Mission..............................................................................................................3
1.6 Document Outline..............................................................................................4
2 Methodology..............................................................................................................4
2.1 Technology Roadmapping................................................................................5
2.2 Technology Insertion Roadmapping (TIRM) .....................................................5
2.3 Aerospace and Defence Technology Framework.............................................6
3 Market Drivers and Constraints.................................................................................6
3.1 Market Sectors..................................................................................................6
3.1.1 Military Aircraft...............................................................................................6
3.1.2 Commercial Aircraft.......................................................................................6
3.1.3 Regional and Corporate Aircraft....................................................................7
3.2 Market Drivers...................................................................................................7
3.2.1 Cost of Ownership.........................................................................................7
3.2.2 Reliability and Availability..............................................................................8
3.2.3 Airworthiness.................................................................................................9
3.3 Market Constraints............................................................................................9
4 System Requirements..............................................................................................11
4.1 Systems Requirement Overview.....................................................................11
4.2 System Requirements Map.............................................................................13
5 DPHM Technologies................................................................................................14
6 Canadian DPHM Capabilities and Gaps..................................................................15
6.1 Market Focus...................................................................................................15
6.1.1 Military Aircraft.............................................................................................15
6.1.2 Commercial Aircraft.....................................................................................15
6.1.3 Regional Aircraft..........................................................................................15
6.2 DPHM Capabilities..........................................................................................15
6.2.1 Military Aircraft.............................................................................................15
6.2.2 Commercial Aircraft.....................................................................................15
6.2.3 Regional Aircraft..........................................................................................15
6.3 Canadian DPHM Gap Assessment.................................................................15
7 Technology Implementation Opportunities..............................................................16
7.1 DPHM Working Group.....................................................................................16
7.2 Technology Demonstration Projects Overview ...............................................16
7.3 BHTI1 - Individual Aircraft Usage Monitoring..................................................19
7.4 BHTI2 - Development of Structures with Embedded Sensors.........................20
7.5 CB1 - FMEA/Field Diagnostic Interoperability.................................................21
7.6 CB2 - Interpretation of Trends and Multivariate Correlations..........................22
7.7 HW - DPHM Requirements for Aircraft Subsystems.......................................23
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7.8 NP1 - Development of a 3D Standoff Scanner for Aircraft NDI.......................24
7.9 NP2 - Develop a 3D Non-contact System for Measuring Airframe Deflections
during Testing..............................................................................................................25
7.10 NP3 - Develop a Rapid 3D Non-contact System Capable of Reverse
Engineering of As-Built and As-Repaired Aircraft........................................................26
7.11 LPTI - Prognosis and Emission Mitigation for DPHM Infrastructure................27
7.12 SAL - Develop and Demonstrate DPHM Benefits on Legacy Fleet.................28
7.13 PWC1 - Maintenance Intervention Planning...................................................29
7.14 PWC2 - Maintainability Tracking and Rapid Maturing Process.......................30
7.15 PWC3 - Test Results Monitoring and Diagnostics..........................................31
7.16 PWC4 - Micro-electromechanical (MEMS)Systems for Fire Detection...........32
7.17 PWC5 - Mobile Phone Engine Data Transfer..................................................33
7.18 PWC6 - Wireless New Engine Sensors ..........................................................34
8 Recommendations...................................................................................................35
9 Definitions................................................................................................................36
10 References..........................................................................................................38
Annex A - Inventory of Relevant DPHM Activities...........................................................39
Annex B - Aeropropulsion DPHM Requirements and Technology Descriptors..............53
B1 Systems Requirements..............................................................................................53
B1.1 Systems Requirements Overview......................................................................53
B1.2 System Functionality Map...................................................................................54
B1.3 Data Collection and Communication..................................................................55
B1.4 Diagnostics.........................................................................................................55
B1.5 Fault Detection...............................................................................................55
B1.6 Fault Isolation.................................................................................................55
B1.7 Prognostics........................................................................................................56
B1.7.1 Failure Mode, Effects and Criticality Analysis (FMECA)..............................56
B1.7.2 Component Life Tracking............................................................................57
B1.7.3 Life Remaining Analysis..............................................................................58
B1.7.4 Performance Trending.................................................................................59
B1.7.5 Fault Prediction............................................................................................59
B1.8 Health Management...........................................................................................59
B1.8.1 Fault Assessment........................................................................................60
B1.8.2 Fault Reporting............................................................................................60
B1.8.3 Supply Chain Integration.............................................................................60
B1.8.4 Fault Accommodation..................................................................................60
B2 Technologies............................................................................................................61
B2.1 Advanced DPHM Technologies Overview.........................................................61
B2.2 Metallurgical Life Limit Monitoring......................................................................62
B2.3 Crack Detection and Monitoring.........................................................................63
B2.4 Oil Debris Monitoring..........................................................................................64
B2.5 Gas Path Debris Monitoring...............................................................................64
B2.6 Vibration Analysis...............................................................................................65
B2.7 Physical Alignment.............................................................................................66
B2.7.1 Clearances..................................................................................................66
B2.7.2 Aero-thermodynamic Performance Assessment.........................................66
B2.8 Decision Aids/Reasoning Engines.....................................................................67
B2.8.1 Rules Based Reasoning..............................................................................67
B2.8.2 Case Based Reasoning...............................................................................67
B2.8.3 Model Based Reasoning.............................................................................68
B2.8.4 Neural Networks..........................................................................................68
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B2.9 Knowledge Discovery and Data Mining.............................................................68
B2.10 Data Fusion......................................................................................................69
B2.11 Health Management/Supply Chain Integration................................................69
B2.11.1 Integrated Maintenance Decision Environment.........................................69
B2.11.2 Competency Assessment and Just-In-Time Training................................69
Annex C – DPHM Standing Working Group Steering Committee Terms of Reference..71
Annex D – Aircraft DPHM Montreal Workshop Attendee List.........................................73
Annex E – Aircraft DPHM Ottawa Workshop Attendee List............................................75

List of Tables
Table # Title Page
1 Aircraft Systems DPHM Systems Requirements Map 13
2 Aircraft Systems DPHM Technologies Map 14
3 DPHM Technology Insertion Project Summary Table 17-18
B-1 DPHM Top Level System Functionality Map 54
B-2 Advanced JSF Condition Based Maintenance Technologies 61
List of Figures
Figure Title Page
#
1 The Technology Roadmap Process 5

2 Representative DPHM System Block Diagram - JSF 11
3 Representative DPHM System Block Diagram – Rotorcraft (M. 12
Augustin, Bell Helicopters, November 18th, 2004)
B-1 DPHM Systems Evolution 54
B-2 F100 Seeded Fault Engine Test DPHM Technologies 58

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1 Introduction
1.1 Background
This Technology Insight Document is the product of collaboration between Industry Canada, the
Canadian aerospace industry and the Aerospace Industries Association of Canada (AIAC). The
objective of this activity is to enhance Canadian Aerospace and Defence sector competitiveness
through coordinated and focused government/industry strategic interaction in the area of
Diagnostics, Prognostics and Health Management (DPHM) for aircraft and aircraft systems.
The requirement for this DPHM initiative was identified through consultation with industry and
government stakeholders. This activity builds on existing Canadian industry sector strengths to
support a number of national and international legacy as well as advanced technology
programs, most notably the Joint Strike Fighter (JSF). While the JSF is not the sole focus of
this report, that program has substantively advanced DPHM technology concepts into an
integrated systems approach beginning at the earliest design stages. The JSF Prognostics and
Health Management (PHM) system is considered an “intellectual process leader” within the US
DoD and is used extensively in this document for reference and guidance. Annex A to this
document provides a listing and website references for a number of relevant DPHM R&D
activities or organizations and programs that are supporting DPHM relevant activities.
1.2 Aircraft Diagnostics, Prognostics and Health Management
There has long been a high level of market need, and demand is accelerating significantly for
broader and more effective integrated diagnostic, prognostic and health management systems.
This demand is industry pervasive from regional aircraft where Canada has particular strengths
and interests, to advanced military systems including the JSF, as well as such initiatives as the
Versatile Affordable Advanced Turbine Engines (VAATE) program. It should be noted that
rotary wing aircraft which provided significant impetus to this technology domain in the early
80’s as a result of North Sea oil servicing flight mishaps, continue to define extreme diagnostic
and prognostic technology challenges in support of aircraft such as the V-22 Osprey and Bell
609 as well as conventional rotorcraft.
The technical challenges are numerous and apply to a broad spectrum of primary and enabling
technologies each of which has specific health and usage monitoring sensor and data
management requirements. While this study does address the individual sensor or analysis
technologies that have been developed for specific aircraft and their systems, a primary focus of
this technology project will be the integration of the numerous disparate systems capabilities
into an effective and efficient integrated technology and enterprise system. It is this Health
Management aspect of DPHM that encompasses the enterprise integration functionality as
maintenance decisions will increasing be made on-board aircraft, and rectification planning
decisions taken in an increasingly automated fashion.
A few basic definitions and terminology on which this project is based are provided below and
are largely derived from JSF terminology. It is noted that the JSF does not separate diagnostics
from the health management concept. This study identifies diagnostics as a separate concept
to capture those processes and technologies that are applied to legacy aircraft systems where
DPHM processes or systems are often introduced after the aircraft has entered operational
service.

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• Diagnostics – is the process of determining the state of a component to perform its
function(s) based on observed parameters;
• Prognostics – is predictive diagnostics which includes determining the remaining life or
time span of proper operation of a component; and
• Health Management – is the capability to make appropriate decisions about maintenance
actions based on diagnostics/prognostics information, available resources, and operational
demand.
1.3 Aircraft Sub-systems
To address differing DPHM needs and technology enablers the aircraft will be partitioned into
four sub-system or conceptual groupings which are listed immediately following and further
described in subsequent paragraphs:
• Aero-propulsion systems;
• Aircraft structures;
• Ancillary systems; and
• DPHM systems integration components.
1.3.1 Aero-propulsion Systems
Aero-propulsion systems are considered to encompass the primary and auxiliary power units on
an aircraft including relevant subsystems and include:
• Primary propulsion units used to generate thrust or lift indirectly;
• Auxiliary propulsion units, typically gas turbines, that are used to generate customer
services including pneumatic or electric services;
• Gearboxes, driveshafts or other mechanical systems that are driven by primary or auxiliary
power units; and
• Propellers, ducted fans and helicopter rotor blades or other thrust or lift generating devices
of a similar nature.
1.3.2 Aircraft Structures
Although the term aircraft structures can be taken to include all structural elements of an aircraft
and it’s subsystems, for the purposes of this initiative, the aircraft structure is considered to
consist of the airframe including: fuselage, wings, flight controls surfaces, and the main and tail
rotors of a rotary-wing aircraft. Structural materials of interest include metallics, plastics,
composites of all forms and types, and hybrid materials.
1.3.3 Ancillary Systems
The ancillary systems category is intended to capture all other aircraft sub-systems for which
DPHM technologies are deemed necessary from economic, reliability or safety perspectives. A
partial list of these systems includes the following:
• Environmental control systems;
• Electric power and power distribution systems;
• Brakes;
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• Wheels and tires;
• Fuel and fuel distribution systems;
• Hydraulic systems; and
• Military aircraft specific systems.
Note that avionics systems are not specifically included in the above listing as their reliability is
such that typical Mean-Time-Between-Failure (MTBF) for aviation electronics components often
represents a significant portion of the total aircraft service life, and these systems are
characteristically well served by built-in-test functionality that provides highly discriminating
failure information.
1.3.4 DPHM Systems Integration
A final functional component is introduced to address the information technology and systems
integration concepts and technologies that are necessary to effectively capture and
communicate DPHM information to both on-board and off-board systems and processes.
This technology component also includes adaptive control concepts for all aircraft systems.
While adaptive control technologies have been widely implemented in certain areas, there is
always the potential for expanding functionality of adaptive control strategies to other systems.
1.4 Vision
A proposed vision statement follows:
“The Canadian aerospace industry is globally recognized as a preferred source of diagnostics,
prognostics and health managements systems, products and services.”
1.5 Mission
World-class Canadian DPHM systems, products, and services will be developed, refined and
demonstrated through a number of technology demonstration projects that are structured within
a focused Technology Implementation Program.
Specific objectives for the DPHM Technology Implementation Program are as follows:
• Identify, research, and prioritize critical system requirements and performance goals;
• Define and prioritize DPHM sub-system technologies, as well as pervasive technology
areas;
• Identify, assess and rank in terms of importance DPHM market drivers, technology drivers,
and product feature concepts;
• Identify and quantify Canadian and global technology capabilities and characterize any
current and significant gaps in the Canadian Aerospace sector; and
• Define a DPHM Technology Implementation Program involving one or more DPHM
technology demonstration projects.

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1.6 Document Outline
This document is presented in the following order:
• Introduction: In the introductory section, the background to this activity is provided to
scope the project in terms of functionality and systems application.
• Methodology: Technology roadmapping and a new and rapid roadmapping process called
the Technology Insertion Roadmap (TIRM) are described in order to situate the reader with
respect to the TID which is the first step in the TIRM process.
• Market Drivers: The market requirements by sector for DPHM systems functionality are
briefly described.
• System Requirements: The overall DPHM environment is discussed in terms of major
functional requirements.
• Technologies: Technologies, both primary and enabling, are described in the context of
global and Canadian aerospace environments.
• Canadian Gap Assessment: Based on DPHM market drivers, system requirements and
the technology requirements, an overview of Canadian strengths will be presented so that
areas where focused investment would provide greatest impact in this market segment can
be identified.
• Concluding material: Conclusions and recommendations for future or follow-on activities
are presented. The concluding material also includes the initial description of the
Technology Implementation Program with insertion projects briefly introduced. References
and terminology/definitions are also provided in the concluding material.
• DPHM Global Activity Inventory: Annex A provides a listing of the DPHM activities, or
organizations that support DPHM activities that have been considered in the generation of
this Technology Insight Document. There is no intent to provide an exhaustive description
of these projects or organizations but rather to provide website or document content that can
be used by readers of this document in performing additional individual research.
• Aeropropulsion Systems Requirements and Technology Descriptors: Annex B
contains the systems requirements and technology narratives from the original
Aeropropulsion and Aircraft Mechanical Systems Technology Insight Document Version 0.3
dated 19 March 2004.
• DPHM Standing Working Group Steering Committee Terms of Reference: Annex C
contains proposed terms of reference for a Steering Committee whose purpose is to
organize a standing DPHM Working Group.
• Aircraft DPHM Montreal Workshop Attendee List: Annex D contains a listing of attendees
at the Montreal DPHM Workshop held on June 22nd, 2004 and their contact informaton.
• Aircraft DPHM Ottawa Workshop Attendee List: Annex E contains a listing of attendees
at the Ottawa DPHM Workshop held on November 18th, 2004 and their contact informaton.
2 Methodology
This DPHM initiative forms an element of a cohesive and far-ranging strategy implemented by
Industry Canada and AIAC. It is founded on the Aerospace and Defence Technology
Framework as well as an abbreviated Technology Roadmapping process that has been
developed and trialled by Industry Canada and AIAC.
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The roadmapping process is first described in general terms in order to understand the
abbreviated process which is used herein - Technology Insertion Roadmapping (TIRM). The
Aerospace and Defence Technology Framework is also briefly described as it is considered to
be a foundation document to this effort.
2.1 Technology Roadmapping
The technology roadmap as a process originated in the early 1980’s when companies such as
Motorola began to utilize roadmapping to ensure that short, medium and long term product
development and technology issues were well understood and that investment was apportioned
appropriately. Industry Canada began their roadmap initiative in 1995 and published a
document entitled “Technology Roadmapping: A Guide for Government Employees” [1]. Other
reference information on the Technology Roadmap Process can be found at the Sandia
National Laboratories website [2].
Since 1995, the Government of Canada has sponsored or participated in a significant number of
technology roadmaps. One of these was the “Aircraft Design, Manufacturing and Repair &
Overhaul (Ontario Pilot)” roadmap which was conducted in 1996 [3]. This pilot project roadmap
identified a number of key topics of interest and also contributed to the definition of need for this
DPHM project. In the Pilot Roadmap study, Integrated Health and Usage Monitoring was
identified as one of the 6 “Critical” Maintenance, Repair and Overhaul technologies.
The roadmapping process is described in the following diagram to situate the reader in terms of
where this study fits within the overall Industry Canada roadmapping and TIRM processes:
Figure 1 – The Technology Roadmap Process

Step 1 – Demand Side

Identify market drivers
and characteristics that
will define demand in
the market in the period
2004-2009. Step 2 – Supply Side

Identify the functional
/performance
requirements and
characteristics Step 3 – Technology
necessary to capture
market share. Identify technology
capabilities, gaps and
priorities that need to Step 4 – Follow Up
be addressed to
deliver the required Generate a Technology

products. Roadmap Report,
initiate technology

implementation. And
periodically review the

roadmap.

2.2 Technology Insertion Roadmapping (TIRM)
The TIRM is a high impact technology roadmap that is performed in an abbreviated timeframe,
typically six months. The more conventional roadmap process as defined at [1] will be
completed in 24 months at a cost of $200K or more, excluding the costs of in-kind government
and industry participation. A TIRM may be appropriate if a significant quantity of reference
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material already exists, and roadmap or roadmap-like activities have already been pursued in
Canada or elsewhere. Simply stated, the focus of the TIRM is to define a Technology
Implementation Program that will consist of one or more technology insertion projects. The
TIRM follows the same process as the more conventional roadmap, although a number of
steps, including consultations, may be streamlined.
This project addresses the first three steps in the TIRM and culminates in the generation of the
TID. The TID is refined in the fourth step of the TIRM, although the primary intent of the last
step in the TIRM is to generate a Technology Implementation Program that consists of one or
more technology insertion projects.
2.3 Aerospace and Defence Technology Framework
The reader is invited to review the Aerospace and Defence Technology Framework [4] which
serves as a foundation document for this TIRM process and which will be continuously
improved through the performance of this and future roadmapping activities.
The Aerospace and Defence Technology Framework provides a common lexicon and
understanding of the aerospace and defence technology structure and definitions. The
Technology Framework begins by defining a technology evolutionary cycle and terminology for
each of the phases. The definition of the technology development cycle provides clarification on
those phases where government investment emphasis and interest is desired and appropriate.
3 Market Drivers and Constraints
3.1 Market Sectors
The need for, and implementation of DPHM concepts and systems will be influenced by market
sector characteristics. Three market sectors are defined for the purposes of this study as
follows:
• Military aircraft;
• Commercial aircraft; and
• Regional and corporate aircraft.
3.1.1 Military Aircraft
Military aircraft users are typically early adopters of technology and often significantly underwrite
the cost of developing and proving new technologies. This market segment includes all aircraft
and rotorcraft that are used by military or paramilitary users but excluding those aircraft that are
commercially certificated and used by the military in a manner similar to that of a commercial
operator.
3.1.2 Commercial Aircraft
This market segment is characterized by large, typically twin aisle, aircraft that are used for long
flights of durations greater than 3 hours as well as narrow-body or single aisle aircraft. Aircraft
acquisition and operational costs are such that the cost of implementing DPHM technologies
can often be readily substantiated. Guaranteed operational cost programs however, will tend to
shift the responsibility for DPHM systems from the operator of these large commercial aircraft to
the MR&O services providers.
By way of example, in a recent presentation, Mr Jean-Pierre Daniel, from Airbus Industries
pointed out that structural health management technologies have advanced to the point where
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