[PPT] - F-35 Joint Strike Fighter Structural Prognostics and Health PowerPoint Presentation

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F-35 Joint Strike Fighter Structural Prognostics and Health Management An Overview

Tim Fallon - JSF Program Office Devinder Mahal - JSF Program Office Iain Hebden – BAE Systems

2009 ICAF Conference Rotterdam

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Air Vehicle Service Life

Ninety percent of all delivered JSF Air Vehicles, by variant, shall achieve either 30 years of operation or 8000 flight hours

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Structural Prognostics and Health Management (SPHM)

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Structural Prognostics and Health Management (SPHM)

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Overview

Enterprise Health Management SPHM Goals System Overview Air Vehicle Off Board Fleet Management

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Structural Prognostics and Health Management (SPHM)

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PHM …a design attribute of a JSF

Lethal Survivable Supportable Affordable

A Highly Supportable, State of the Art Prognostics

and Health Management (PHM) System

TODAY TODAY JSF JSF O&S O&S

R&D R&D and and Production Production

O&S O&S

R&D R&D and and Production Production

JSF is committed to reducing O&S costs – Legacy is unaffordable!

A supportable and affordable next generation fighter needs…. JSF is committed to not doing business as usual

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Structural Prognostics and Health Management (SPHM)

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PHM Architecture

Air Vehicle On-Board Health Assessment Air Vehicle/Support System Interface Auto Log & Off-Board PHM

Automated Pilot/
Maint. Debrief
Off-Board

Prognostics − Trending − Life Mgmt

Intelligent Help
Store/Distribute

PHM Information

Mission Critical PHM Data Displays and Controls Maintenance Panel

.

PMA

Flight Critical

PHM Area Managers

Provides:

In-Flight Data Link

PVI

IETMs Consumables On-Board Diagnostics Fault/Service Info

Database

AV-Level Info

Management

Intelligent FI
Prognostics/Trends
Auto. Logistics

Enabling/Interface

Hosted in ICP

AMD/PMD

ALIS

AVPHM

Hosted in ICP Fault Accommodation Status via ICAWS

Portable Memory Device (PMD)

Propulsion PHAM

Mission Systems

Airframe Vehicle Systems

Crash Recorder NVM

Maintainer Vehicle Interface

Sensor Fusion
Model-Based Reasoning
Tailored Algorithms
Systems Specific

Logic / Rules

Feature Extraction

Methods Used:

Decision Support
Maintenance Planning
Condition-Based Maint.
Efficient Logistics

Results In:

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Structural Prognostics and Health Management (SPHM)

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SPHM Goals

Minimize maintenance while maintaining safety
Eliminate scheduled inspections - Goal is on-condition

maintenance

Achieve condition based maintenance at minimum cost
Individual aircraft tracking
Fully automated
Support structural prognostics
Minimize dedicated SPHM sensors
SPHM integral part of AVPHM and OBPHM
Capability to accept emerging technologies

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Structural Prognostics and Health Management (SPHM)

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SPHM Capabilities

Air Vehicle SPHM Capability

Recording of ‘raw’ PHM data
Structural Events (Overloads)
Structural Usage Indices

– Aircraft Parameters – Control surface usage – Door usage – Landing data

Corrosion Environment Sensing

OBPHM SPHM Planned Capability

Individual Aircraft Tracking

– Fatigue life consumption at selected critical locations. – Remaining life estimate for maintenance and operational planning – Corrosion prediction & tracking models

Fleet management, lead aircraft,

identification of damaging manoeuvres.

Usage compared to design spectra
Flight event replay
Loads/Environment Spectra Survey

(L/ESS) - PHM related data

Data mining

– maintenance, repair, manufacturing history, usage indices

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Structural Prognostics and Health Management (SPHM)

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SPHM Functions

Operational Loads Measurement

– Strain gage – Parametric models – Safe-Life and Damage Tolerant models

Structural Overload Measurement
Auxiliary Structural Data collection
Corrosion Environment Monitoring

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Structural Prognostics and Health Management (SPHM)

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SPHM Strain Sensor Locations (STOVL)

Wing Root – BH 496 Wing Root – LH Shear Wing Root – LH Bending Flaperon Hinge Attach LH Aft Fuselage Actuator Lug LH Vertical Tail Bending Attachment LH Vertical Tail Shear Attachment LH Aft Fuselage Kicked Keel Centre Fuselage Bending Forward Fuse Canopy Sill

SPHM Strain Sensor Mirrored Locations

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Structural Prognostics and Health Management (SPHM)

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Strain Sensors

JSF philosophy – strain sensors are for model development, verification

and refinement

– All Strain Sensors are in baseline design and would require an engineering change to remove them. Full Bending and Shear Bridges.

One side of aircraft instrumented

– Other side validated with loads aircraft instrumentation

Can be in difficult to access locations

– Primary and Backup gages – Will not be maintained – operate until they expire

All aircraft will be tracked – primary means is parametric equations and

dynamic models

P+ P- S+ S- B

Cable - Twisted Shielded pair Multi core Shielded Splice

Tag Strip

σ1 σ2

τ2 τ1

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Structural Prognostics and Health Management (SPHM)

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Gauge 2

Strain Sensors

JSF philosophy – strain sensors are for model development, verification

and refinement

– All Strain Sensors are in baseline design and would require an engineering change to remove them. Full Bending and Shear Bridges.

One side of aircraft instrumented

– Other side validated with loads aircraft instrumentation

Can be in difficult to access locations

– Primary and Backup gages – Will not be maintained – operate until they expire

All aircraft will be tracked – primary means is parametric equations and

dynamic models

σ1 σ2

τ2 τ1

P+ P- S+ S- B

Tag Strip

Gauge 1 P +

Tension

Compression

Monitored and recorded at 320 Hz. Time Synched.

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Structural Prognostics and Health Management (SPHM)

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Indicative Positions of Strain Gauges

Sensor 1 – LH Vertical Tail Attachment FS 575

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Structural Prognostics and Health Management (SPHM)

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Sensor 2 – LH Vertical Tail Attachment FS 609

Indicative Positions of Strain Gauges Frame 609 LH Side – View Looking Inboard Frame 609 LH Side – View Looking Outboard Primary Bridge Backup Bridge backup primary backup primary

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Structural Prognostics and Health Management (SPHM)

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Sensors 3 LH Aft Fuselage Kicked Keel – FS 625

Indicative Positions of Strain Gauges

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Structural Prognostics and Health Management (SPHM)

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Indicative Positions of Strain Gauges

Tag Strip

Sensors 4 LH Aft Fuselage Kicked Keel – FS 625

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Structural Prognostics and Health Management (SPHM)

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2 1 6 5 4 3 8 7

OUTBOARD UP

10 9 14 13 11 12 15 16

Sensors 5&6 – LH Wing Carry Thru Bulkhead 450

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Structural Prognostics and Health Management (SPHM)

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Sensor 7 – LH Wing Rear Spar FS550

10 9 14 13 11 12 15 16

Indicative Positions of Strain Gauges

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Structural Prognostics and Health Management (SPHM)

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Indicative Position of Strain Gauges

UP FORWARDS

Primary Backup

Canopy Sill Longeron, RH Canopy Latch Fitting

View Looking Inbd and Up at RHS

(For Orientation Purposes)

Sensor 8 – RH Canopy Sill FS244

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Structural Prognostics and Health Management (SPHM)

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Sensor 9 – LH Wing Carry Thru Bulkhead 496 Sensor 9 Location

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Structural Prognostics and Health Management (SPHM)

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SPHM Sensor 10 - Centre Fuselage Bending

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Structural Prognostics and Health Management (SPHM)

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RIO to Sensors Wiring Routes

RIO #4 (A) RIO #1 (A & B) RIO #3 (A, B, & C)

RIO (VSP)

RIO #2 (B & C) RIO #4 (B) RIO #4 (C)

Strain Sensors common to all three a/c variants Fully Shielded Wire. Note: Cable runs not representative

8 9 10 7 6 5 1 2 3 4

VS Network

Strain Gauge Identification Key 1. LH Vertical Tail Attachment - (mid spar lower lug) 2. LH Vertical Tail Attachment - (rear spar lower lug) 3. LH Horizontal Tail - (actuator horn) 4. LH Horizontal Tail - (hinge spar) 5. LH Wing Root - (Frame 450 bending) 6. LH Wing Root - (Frame 450 Shear) 7. LH WR Rear bulkhead 8. Canopy Sill 9. Centre Fuselage Bending 10. Flaperon Attach

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Structural Prognostics and Health Management (SPHM)

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12 bit ADC

Remote Input Output Device

JSF RIO Specification of System Requirements

Vs V+ V- VX ∆V Processing

Range of ∆V= ±100mV Range of Vx= 0-10V RIO Scaling “Value”=(∆V/VX)*10000 Range=±100

∆V/VX

Bus Message

Integer Value
Range ±1000

l.s.b = 0.1

For a Full Poisson Bridge Circuit:

RIO interface

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Structural Prognostics and Health Management (SPHM)

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Aircraft Parameters

Over 100 parameters monitored AND

RECORDED continuously

– 320 Hz Strain data, written as 4 words per 80 Hz record – 80 Hz linear inertial data – 20 Hz air data, control surface, door, engine parameter, etc – 1 Hz on discretes

Recorded from BF-1 and on
Initial estimate is ~200 MB per flight hour
Expect <100 MB / hr at end of SDD
Additional data compression possible both on and
ff board

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Structural Prognostics and Health Management (SPHM)

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Aircraft Parameters

Inertia and Strain Sensor Data

Parameter Minimum Sample Rate per second Rationale Notes Longitudinal Acceleration at the Centre of Gravity 80 Lateral Acceleration at the Centre of Gravity 80 Normal Acceleration at the Centre of Gravity 80 Measured Longitudinal Load Factor (Nx) 80 Measured value at Centre of Gravity not available. Translation to be perfomed offboard Measured Lateral Load Factor (Ny) 80 Measured value at Centre of Gravity not available. Translation to be perfomed offboard Measured Normal Load Factor (Nz) 80 Measured value at Centre of Gravity not available. Translation to be perfomed offboard Body Axis X Angular Acceleration 20 Body Axis Y Angular Acceleration 20 Body Axis Z Angular Acceleration 20 Roll Rate 20 Pitch Rate 20 Yaw Rate 20 Roll Attitude 20 Pitch Attitude 20 Heading 20 Yaw attitude not available as a specfic parameter Body Axis X Velocity 20 Body Axis Y Velocity 20 Body Axis Z Velocity 20 Strain sensor values CTOL (10) 320 Strain sensor values STOVL (10) 320 Strain sensor values CV (13) 320

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Structural Prognostics and Health Management (SPHM)

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Aircraft Parameters

Air Data

Parameter Minimum Sample Rate per second Angle of Attack 20 Static Pressure Measured 20 Total Pressure Measured 20 Angle of Sideslip 20 Air Density Ratio 20 Baro Setting 20 Pressure Altitude 20 Baro Reference Altitude 20 Altitude Rate 20 Mach Number 20 Pressure Ratio 20 Dynamic Pressure 20 Impact Pressure 20 True Freestream Air Temperature 20 Total Temperature 20 Calibrated Airspeed 20 Equivalent Airspeed 20 True Airspeed 20

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Structural Prognostics and Health Management (SPHM)

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Aircraft Parameters

Mass Data

Parameter Minimum Sample Rate per second Rationale Notes Weight of empty aircraft Aircraft gross weight to be calcualted offboard using basic weight, expendables and consumables data Aircraft BL Centre of Gravity Position 80 Aircraft WL Centre of Gravity position 80 Aircraft FS Centre of Gravity position 80 Store Quantities Stations 1 to 12 On Change Store Type Stations 1 to 12 On Change Rack Type Stations 1 to 12 On Change Ejector Type Station 1 to 12 On change Max Fuel for each Tank 1 Tanks F1, F2L, F2R, F3L, F3R, F4L, F4R, F5L, F5R, LW, RW, ELW, ERW Min Fuel for each Tank 1 Tanks F1, F2L, F2R, F3L, F3R, F4L, F4R, F5L, F5R, LW, RW, ELW, ERW Stores mass to be calculated offboard Simulated store is accounted for in stores data.

Miscellaneous Data

Parameter Minimum Sample Rate per second Rationale Notes Radar Altimeter 1 Source of accurate low level altitude data STOVL Mode 20 Track 1 True Heading 1 Vertical Velocity 1 Velocity East 1 Velocity North 1

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Structural Prognostics and Health Management (SPHM)

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Aircraft Parameters

Control Surface, Doors and Canopy

Parameter Minimum Sample Rate per second Left Aileron Angular Position (CV) 20 Right Aileron Angular Position (CV) 20 Left Flaperon Angular Position 20 Right Flaperon Angular Position 20 Left Horizontal Tail Angular Position 20 Right Horizontal Tail Angular Position 20 Left LEF Angular Position 20 Right LEF Angular Position 20 Left Outboard LEF Angular Position (CV) 20 Right Outboard LEF Angular Position (CV) 20 Left Vertical Tail Angular Position 20 Right Vertical Tail Angular Position 20 Canopy Enumerated Position 1 Landing Gear Door Enumerated Positions 1 STOVL Door Enumerated Positions 1 Weapon Bay Door Enumerated Positions (Inboard Left, Outboard Left, Inboard Right, Outboard Right) 20 Weapon Bay Door Angular Positions (Inboard Left, Outboard Left, Inboard Right, Outboard Right) 20 Refuel Receptacle Door Enumerated Positions 1 Refuel Probe Door Enumerated Positions 1

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Structural Prognostics and Health Management (SPHM)

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Aircraft Parameters

Landing, Launch and Arresting Gear

Parameter Minimum Sample Rate per second Left Main Landing Gear Enumerated Position 1 Right Main Landing Gear Enumerated Position 1 Nose Landing Gear Enumerated Position 20 Left Main Landing Gear Weight on Wheels 20 Right Main Landing Gear Weight on Wheels 20 Nose Landing Gear Weight on Wheels 20 Left Main Landing Gear Wheel Speed 20 Right Main Landing Gear Wheel Speed 20 Nose Landing Gear Wheel Speed 20 Launch Bar Up 1 Launch Bar Down 1 Launch Bar Brakes 1 Arrestor Gear Retracted 1 Arrestor Gear Deployed 1 Cockpit Parking Brake Engaged/Not Engaged 1

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Structural Prognostics and Health Management (SPHM)

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Aircraft Parameters

Engine Data

Parameter Minimum Sample Rate per second Estimated Total Gross Thrust Feedback 20 Estimated Main Nozzle Thrust 20 Main Engine Core Speed 20 Main Engine Fan Speed 20 Main Engine Core Speed - Physical (%) 20 Main Engine Fan Speed - Physical (%) 20 Ready to Convert to Jet 20 Ready to Convert to Wing 20 Thrust Split Achieved 20 Lift Fan Nozzle Pitch Angle Position 20 3BSD Pitch Angle Position 20 3BSD Yaw Angle Position 20 Longitudinal Thrust Split Feedback 20 Roll Post Thrust Split Feedback 20 Estimated Left Roll Nozzle Thrust Feedback 20 Estimated Right Roll Nozzle Thrust Feedback 20 Estimated Lift Fan Thrust 20 Lift Fan Speed - Physical 20 Lift Fan Speed - RPM 20 Lift Fan / Clutch Status Word 20

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Structural Prognostics and Health Management (SPHM)

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Overload Monitoring

CER/CEA/CEM

– Conditional Event Reporting, Analysis and Maintenance – Health Reporting Code generated

Air Vehicle

– Initial

Overload tracking Nz vs. roll rate

– Interim

Add: Hard landing & Over speed
Add: ICAWS

– End of SDD

Update to Overload

– Monitor loads at key locations – Target specific inspections – New process – ATLAS Loads approach

Off Board

– Quality controlled and corrected/verified signals – Overload analysis and display – Maintenance Action generated

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Structural Prognostics and Health Management (SPHM)

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Usage/Auxiliary Data Collection

Usage data tables accumulated onboard the air

vehicle

– Prevents against data loss and provides comparison to design – In segregated memory – not overwritten – Occurrence and Time accumulation – Additional System Health check – Additional Calculated loads peak/valley tables

DISTRIBUTION STATEMENT A: Approved for Public Release: Distribution is Unlimited

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Structural Prognostics and Health Management (SPHM)

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Auxiliary Data

Life Cumulative Flight-by- flight Max number of flights stored before overwrite Time at Mach-Altitude by Gross Weight Band X 10 Time at AoA-Dynamic Pressure-Side slip by Mach No X 10 Cockpit Pressurisation Cycle Count X 10 Pressure-Altitude From-To Spectrum X 10 Flaperon Movement X 10 Rudder Movement X 10 Horizontal Tail Movement X 10 Speed Brake Deployment Count X 10 Time in Speed Range for Speed Brake Deployment X 10 Canopy Cycle Count X N/A Landing Gear Cycle count in Maintenance Mode X N/A Weapon Bay Door Cycles X N/A Weapon Bay Door Open Time in Speed Range X N/A Refuel Receptacle Door Cycles X N/A Refuel Receptacle Door Open Time in Speed Range X N/A STOVL Door Cycles X N/A Refuel Probe Door Cycles (STOVL) X N/A Refuel Probe Door Open "Time in Speed Range" X N/A Landing Gear Cycle count in air X N/A LESS Flight Spectra Ny X 10 Nz X 10 p X 10 pdot X 10 IAT Flight Spectra Nz X 10 Nz*W X 10

Storage Method for Usage Data

Altitude Monitoring Attitude Monitoring Cockpit Pressurisation Control Surface Movement On Ground Monitoring In-Flight Door Opening In-Flight Landing Gear Cycles In-Flight Occurrence Spectra

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Structural Prognostics and Health Management (SPHM)

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Auxiliary Data

Life Cumulative Flight-by- flight Max number of flights stored before overwrite No of In-flight Refuels (CTOL) X N/A No of Boom Contacts (CTOL) X N/A No of In-flight Refuels (Probe) (STOVL) X N/A IAT Severity Indices (Peak-Valley format) Forward Fuselage Severity Index (CTOL, STOVL) X 10 Wing Root Severity Index (CTOL, STOVL) X 10 Wing Mid-Span to Tip Severity Index (CTOL, STOVL) X 10 Horizontal Tail Severity Index (CTOL, STOVL) X 10 Centre Forward/Aft Fuselage (CTOL, STOVL) X 10 Vertical Tail Severity Index (CTOL, STOVL) X 10 IAT Severity Indices (From-To format) Forward Fuselage Severity Index (CTOL, STOVL) X 10 Wing Root Severity Index (CTOL, STOVL) X 10 Wing Mid-Span to Tip Severity Index (CTOL, STOVL) X 10 Horizontal Tail Severity Index (CTOL, STOVL) X 10 Centre Forward/Aft Fuselage (CTOL, STOVL) X 10 Vertical Tail Severity Index (CTOL, STOVL) X 10 Conventional Takeoff by Gross Weight Band X 10 Vertical Takeoff by Gross Weight Band (STOVL) X 10 Rolling Vertical Takeoff by Gross Weight Band (STOVL) X 10 Conventional Landing by Gross Weight Band X 10 Vertical Landing by Gross Weight Band (STOVL) X 10 Rolling Vertical Landing by Gross Weight Band (STOVL) X 10 Touch and Go Landing by Gross Weight Band X 10 Landing Load Special Event X 10

Storage Method for Usage Data

Takeoff and Landing Monitoring In-Flight Refuel Monitoring In-Flight Severity Index Spectra

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Structural Prognostics and Health Management (SPHM)

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Sample From/To Table

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Nz < -3.5

3.5 < Nz < -2.5
3.0 < Nz < -2.5
2.5 < Nz < -2.0
2.0 < Nz < -1.5
1.5 < Nz < -1.0
1.0 < Nz < -0.5
0.5 < Nz < 0.0

0.0 < Nz < 0.5 0.5 < Nz < 1.0 1.0 < Nz < 1.5 1.5 < Nz < 2.0 2.0 < Nz < 2.5 2.5 < Nz < 3.0 3.0 < Nz < 3.5 3.5 < Nz < 4.0 4.0 < Nz < 4.5 4.5 < Nz < 5.0 5.0 < Nz < 5.5 5.5 < Nz < 6.0 6.0 < Nz < 6.5 6.5 < Nz < 7.0 7.0 < Nz < 7.5 7.5 < Nz < 8.0 8.0 < Nz < 8.5 8.5 < Nz < 9.0 9.0 < Nz < 9.5 9.5 < Nz < 10.0 10.0 < Nz < 10.5 10.5 < Nz < 11.0 Nz > 11.0 1 Nz < -3.5 2

3.5 < Nz < -2.5

3

3.0 < Nz < -2.5

4

2.5 < Nz < -2.0

5

2.0 < Nz < -1.5

6

1.5 < Nz < -1.0

7

1.0 < Nz < -0.5

8

0.5 < Nz < 0.0

Occurrences

9 0.0 < Nz < 0.5 10 0.5 < Nz < 1.0 11 1.0 < Nz < 1.5 12 1.5 < Nz < 2.0 13 2.0 < Nz < 2.5 14 2.5 < Nz < 3.0 15 3.0 < Nz < 3.5 16 3.5 < Nz < 4.0 17 4.0 < Nz < 4.5 18 4.5 < Nz < 5.0 19 5.0 < Nz < 5.5 20 5.5 < Nz < 6.0 21 6.0 < Nz < 6.5 22 6.5 < Nz < 7.0 23 7.0 < Nz < 7.5 24 7.5 < Nz < 8.0 25 8.0 < Nz < 8.5 26 8.5 < Nz < 9.0 27 9.0 < Nz < 9.5 28 9.5 < Nz < 10.0 29 10.0 < Nz < 10.5 30 10.5 < Nz < 11.0 31 Nz > 11.0

“From” "To"

Band No. Nzcg Band (g's)

Nz

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Structural Prognostics and Health Management (SPHM)

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Sample Time at Event Table

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 M < 0.1 0.1 < M < 0.2 0.2 < M < 0.3 0.3 < M < 0.4 0.4 < M < 0.5 0.5 < M < 0.6 0.6 < M < 0.7 0.7 < M < 0.8 0.8 < M < 0.9 0.9 < M < 1.0 1.0 < M < 1.1 1.1 < M < 1.2 1.2 < M < 1.3 1.3 < M < 1.4 1.4 < M < 1.5 1.5 < M < 1.6 1.6 < M < 1.7 1.7 < M < 1.8 1.8 < M < 1.9 M>1.9

1

h < 2K 2 2K < h < 4K 3 4K < h < 6K 4 6K < h < 8K 5 8K < h < 10K 6 10K < h < 12K 7 12K < h < 14K 8 14K < h < 16K 9 16K < h < 18K 10 18K < h < 20K Count 11 20K < h < 22K 12 22K < h < 24K 13 24K < h < 26K 14 26K < h < 28K 15 28K < h < 30K 16 30K < h < 35K 17 35K < h < 40K 18 40K < h < 45K 19 45K < h < 50K 20 h > 50K Mach No Band

Altitude Band (feet)

Time at Mach/Altitude

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Structural Prognostics and Health Management (SPHM)

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Example Calculated Load From/To

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Band No WRBM Band (in-lb)

WRBM <-4000K

4000K < WRBM <-3500K
3500K < WRBM <-3000K
3000K < WRBM <-2500K
2500K < WRBM <-2000K
2000K < WRBM <-1500K
1500K < WRBM <-1000K
1000K < WRBM <-500K
500K < WRBM < 0K

0K < WRBM < 500K 500K < WRBM < 1000K 1000K < WRBM < 1500K 1500K < WRBM < 2000K 2000K < WRBM < 2500K 2500K < WRBM ≤ 3000K 3000K < WRBM < 3500K 3500K < WRBM < 4000K 4000K < WRBM < 4500K 4500K < WRBM < 5000K 5000K < WRBM < 5500K 5500K < WRBM < 6000K 6000K < WRBM < 6500K 6500K < WRBM < 7000K 7000K < WRBM < 7500K 7500K < WRBM < 8000K 8000K < WRBM < 8500K 8500K < WRBM < 9000K WRBM > 9000K

1

WRBM <-4000K

2

4000K < WRBM <-3500K

3

3500K < WRBM <-3000K

4

3000K < WRBM <-2500K

5

2500K < WRBM <-2000K

6

2000K < WRBM <-1500K

7

1500K < WRBM <-1000K

8

1000K < WRBM <-500K

9

500K < WRBM < 0K

Occurrences 10

0K < WRBM < 500K

11

500K < WRBM < 1000K

12

1000K < WRBM < 1500K

13

1500K < WRBM < 2000K

14

2000K < WRBM < 2500K

15

2500K < WRBM < 3000K

16

3000K < WRBM < 3500K

17

3500K < WRBM < 4000K

18

4000K < WRBM < 4500K

19

4500K < WRBM < 5000K

20

5000K < WRBM < 5500K

21

5500K < WRBM < 6000K

22

6000K < WRBM < 6500K

23

6500K < WRBM < 7000K

24

7000K < WRBM < 7500K

25

7500K < WRBM < 8000K

26

8000K < WRBM < 8500K

27

8500K < WRBM < 9000K

28

WRBM > 9000K

“From” "To"

WRBM

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Structural Prognostics and Health Management (SPHM)

DISTRIBUTION STATEMENT A: Approved for Public Release: Distribution is Unlimited

Corrosion Sensors

Replace scheduled inspections with “on condition”

inspections

Sensors in 2 locations on SDD aircraft

– Demonstrate reliability and refine models – Growth capability exists as needs emerge – Difficult access, high value locations chosen

Sentinel Resistance sensors

– Resistance changes as pre-calibrated strips on sensor begin to corrode – Tied into aircraft bus to automatically record data at start and end of flight

UP Aft

Sensor 14 (Type A) Sensor 15 (Type B)

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Structural Prognostics and Health Management (SPHM)

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84 day inspection 84 day inspection 84 day inspection 84 day inspection 84 day inspection 84 day inspection 84 day inspection 84 day inspection

Scenario 1 – Sensor output corresponds with inspection data

Corrosion Sensor reports corrosion in same timeframe that

inspection reveals corrosion

– Corrosion repaired – Replacement sensor installed – Aged or new?

Need to understand quality of repair against original coatings.
Validation evidence – requires suitable sample

– Sensor slot widths suitable

No corrosion Corrosion found First slot depleted Corrosion repaired. New Sensor Installed

Inspection Sensor Output

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Structural Prognostics and Health Management (SPHM)

DISTRIBUTION STATEMENT A: Approved for Public Release: Distribution is Unlimited

SPHM Capabilities

Air Vehicle SPHM Capability

Recording of ‘raw’ PHM data
Structural Events (Overloads)
Structural Usage Indices

– Aircraft Parameters – Control surface usage – Door usage – Landing data

Corrosion Environment Sensing
Aircraft Configuration

OBPHM SPHM Planned Capability

Individual Aircraft Tracking

– Fatigue life consumption at selected critical locations. – Remaining life estimate for maintenance and operational planning – Corrosion prediction & tracking models

Fleet management, lead aircraft,

identification of damaging manoeuvres.

Usage compared to design spectra
Flight event replay
Loads/Environment Spectra Survey

(L/ESS) - PHM related data

Data mining

– maintenance, repair, manufacturing history, usage indices

DISTRIBUTION STATEMENT A: Approved for Public Release: Distribution is Unlimited

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Structural Prognostics and Health Management (SPHM)

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Individual Aircraft Tracking

J4773010 9/3/99

SPHM Operational Loads

Monitoring (OLM)

– SPHM Area Manager Fed Various Flight Parameters – Most Data Sources SOF – Time History Captured – Parameter Cycle Counting and Usage Statistics Calculated by SPHM Area Manager – Fatigue Life Expended for Control Points Tracked – Results stored for ALIS download and further force life management – Future updates are table driven, not OFP changes – Requirement for 98% Accurate data collection

M nz p δHT Time

σi σm εa

Cycle

1 xxxx yyyy 2 xxxx yyyy …………. n xxxx yyyy

Mach Altitude

tk tj

it

Time nzW Exceedances

MTy MTx

Individual Aircraft Usage Individual Aircraft Damage

N

σ σ ε

Control Point Damage Index 1 0.155 2 0.231 3 0.224 n 0.196

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Structural Prognostics and Health Management (SPHM)

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Flight Parameters Parameter to Loads Models External Loads Strain Sensor Replication Models Strain Stress *Damage

Config/look-up table.

Allows system to be built in

advance of final algorithm definition

Internal Loads Strain Sensors

IAT Fatigue Damage Calculation

*Damage model for IAT tracking uses same model as design Damage Tolerance for CTOL Initiation Strain Life STOVL and CV

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Structural Prognostics and Health Management (SPHM)

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ALIS Conops

CPE (Servers)

Central Services Kit ALGS Kit

ALOU (Servers)

PMA SOU Servers (GBCU) OMSE OMS WS GDR Base and Squadron Kit

Support Squadron Activities

Operations & Maintenance
Pre- and Post-Mission

PCA

Support ALGS Ops and provide operational data to support PBL management Control Information Flow between Military & Commercial Networks

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Structural Prognostics and Health Management (SPHM)

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SPHM Health Management Screens (notional)

Fatigue status of the airframe

Specified Control Points only Control Point Summary Individual Aircraft Tracking High Usage Anomaly Reports

Corrosion status of the airframe

Sensor locations only

Structural usage metrics
Actual vs. Baseline Usage

Comparisons

Time to Inspection metrics

Dedicated Screens

Remaining Life Estimates

Automatic & interactive capability The Health Management Tools within ALIS will display:

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Structural Prognostics and Health Management (SPHM)

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CTOL Screen Examples (notional)

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DETAILS CONTROL POINT TRACKING INFORMATION FOR ALL AIRCRAFT Projected End of Life or maintenance – Several projections can be produced & End Point can be selected Actual & Baseline DI to compare severity EFH/AFH Ratios Projected Inspection Points Example of a Baseline (based on design/test/updated DADT) & Projected Crack Growth Curve – This projection shows that the aircraft is flying with greater severity than design NOTE : THIS IS A “LIVE” TABLE AND WILL BE AUTOMATICALLY UPDATED FOLLOWING EACH DATA DOWNLOAD Projections can be changed as a result of inspections and can be based on base/squadron/fleet/country/average usage/high usage/etc Filter A/C Variant & Control Point

Variant CTOL Control Point XX Description LH Wing, Rear Spar Attach UAI Flight Hours (AFH) Current Flaw Size (in) Equivalent Flight Hours (EFH) EFH/AFH Projected EFH at AFH=8000 Projected AFH at EFH=8000 Remaining AFH to EFH=8000 Date Flaw Size Flaw Size Flt Hours Date Flaw Size Flt Hours (AFH) Date xx001 985 0.09 1759 1.79 14284 4481 3496 N/A N/A 0.35 7300 Sep-43 0.35 6750 Jul-41 xz452 1253 0.075 1278 1.02 6593 7846 6593 N/A N/A 0.35 7300 Jun-32 0.35 7250 May-32 xx236 1350 0.11 2361 1.75 3224 4574 3224 N/A N/A 0.35 7300 Mar-43 0.35 6820 Jan-40 xx540 2765 0.125 2787 1.01 5173 7938 5173 N/A N/A 0.35 7300 Oct-36 0.35 7275 Sep-36 xz400 1520 0.06 769 0.51 14301 15821 14301 N/A N/A 0.35 7300 Sep-40 0.35 7543 Sep-41 Previous Maintenance Baseline Inspection Point Projected Inspection Point Initial Flaw Size (in) Critical Flaw Size (in) 0.05 1.37

Crack Growth Curve - Control Point XX

0.2 0.4 0.6 0.8 1 1.2 1.4 2000 4000 6000 8000 10000 12000 14000 Flight Time (FH) Flaw Size (inches) Actual Projected Crack Length (in) Baseline Crack Length (in)

7300 FH (Intial Inspection) 6750FH Initial Inspection Flaw Size = 0.35in Actual Flaw Size = 0.09in

Current Flight Hours = 985 Inspection period brought forward to 6750 FH as a result

f projected crack length

Design predicted critical crack length at 14,600FH - sets initial inspection at 7,300FH

Structural Prognostics and Health Management (SPHM)

Control Point Display Screen (Example)

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Structural Prognostics and Health Management (SPHM)

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Control Point Summary (Example Only)

Control Point Summary 2000 4000 6000 8000 10000 12000 1000 2000 3000 4000 5000 6000 7000 8000 9000 Actual Flight Hours Equivalent Flight |Hours EFH Linear (EFH)

EFH=1.288*AFH EFH=AFH DISPLAYS A PICTURE OF WHERE THE FLEET/BASE/SQUADRON ARE WITH REGARDS TO SEVERITY OF FLYING – CAN BE GENERATED FOR EACH CONTROL POINT Can be projected for different baselines, eg. different bases/squadrons/ countries or DADT Analysis. Control Point XX This squadron is currently flying (on average) 29% greater severity than design with respect to this control point

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Structural Prognostics and Health Management (SPHM)

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Individual Aircraft Tracking (Example Only)

SIMILAR INFORMATION TO CONTROL POINT SUMMARY – LISTS DADT SUMMARY FOR ALL CONTROL POINTS FOR INDIVIDUAL AIRCRAFT Could filter on:

EFH
Projected EFH
Projected AFH
AFH to Inspection

Could list all monitored control points or (say) top 20 by EFH or AFH to Inspection Highlight Control Points displaying:

high EFH
Predicted inspections significantly

brought forward in time ALL DATA FOR IAT CAN BE HYPERLINKED WITH AIRCRAFT USAGE SCREENS, EG. EXCEEDENCE PLOTS, LANDING GEAR USAGE, TIME AT MACH-ALT, CONTROL SURFACE USAGE, ETC.

Aircraft Tail No. Variant Entry Into Service Date

No. of Flts

Flight Hours (AFH) XX001 CTOL Jul-14 725 985 Control Point No. Control Point Description Initial Flaw Size (in) Critical Flaw Size (in) Baseline Crack Growth Life (FH) Current Flaw Size (in) Flight Hours (AFH) Equivalent Flight Hours (EFH) EFH/AFH Projected EFH at AFH=8000 Projected AFH at EFH=8000 Remaining AFH to EFH=8000 Date Flaw Size Flaw Size AFH Date Flaw Size AFH Remaining AFH Date 0029 LH Wing, Rear Spar, 0.05 1.37 14600 0.09 985 1759 1.79 14286 4480 3495 N/A N/A 0.350 7300 2043 0.350 6750 5765 2041 0133 LH HT Spar 1 I/B, Rib 4 shear joint 0.01 0.365 16702 0.0135 985 741 0.75 6018 10635 9650 N/A N/A 0.053 8351 2047 0.053 8900 7915 2049 0008 VT Aft root rib, fairing web attachment 0.01 0.34775 16667 0.017 985 1519 1.54 12339 5187 4202 N/A N/A 0.081 8333 2047 0.081 7300 6315 2043 0268 RH Wing Leading Edge Upper Flange BL175 0.01 0.47052 24329 0.026 985 2728 2.77 22156 2889 1904 N/A N/A 0.080 12150 2062 0.080 6350 5365 2039 Sortie Info Summary Projected Inspection Point Control Point Summary Previous Maintenance Baseline Inspection Point

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Structural Prognostics and Health Management (SPHM)

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STOVL/CV Screen Examples (notional)

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Structural Prognostics and Health Management (SPHM)

DISTRIBUTION STATEMENT A: Approved for Public Release: Distribution is Unlimited

Base China Lake Squadron 54 Control Point XX LH Wing, Rear Spar Attach UAI Flight Hours (AFH) Current FLE Current FLE Rate (per 1000FH) Design FLE Rate (per 1000FH) FLE Limit Remaining FLE Projected AFH at FLE Limit Remaining AFH to FLE limit Remaining AFH to 8000FH FLE Flt Hours (AFH) Date xx001 985 0.22 0.22 0.125 1.00 0.78 4477 3492 7015 N/A N/A N/A xz452 1253 0.16 0.13 0.125 1.00 0.84 7831 6578 6747 N/A N/A N/A xx236 1350 0.30 0.22 0.106 0.85 0.55 3825 2475 6650 0.85 3825 Mar-21 xx540 2765 0.35 0.13 0.125 1.00 0.65 7900 5135 5235 N/A N/A N/A xz400 1520 0.10 0.07 0.125 1.00 0.90 15200 13680 6480 N/A N/A N/A Description Projected Inspection Point (click to enter detail - default=25 FH/Month)

Control Point Summary Screen Example

Enter FH/month 22.8 Current FH/month usage (click to view detail) Projected Inspection Point

DETAILS CONTROL POINT TRACKING INFORMATION FOR ALL AIRCRAFT

Base China Lake Squadron 41 UAI FH/Month (Previous 12 months) FH/Month (Life) All 20.3 22.8 z3154 19.1 22.3 z1266 2.6 19.1 xa234 21.9 20.6 xz389 33.2 25.6 yy990 24.6 26.2

SELECT BASE & SQUADRON AND CONTROL POINT TO ANALYSE Click to ENTER user-definable values for projected inspection point calculation Click to view FH histories of squadrons

Current FLE & FLE Rates – should include capability to view graphical comparison between squadrons and bases – see Slides xx.

Projected FH at FLE Limit (highlight a/c that have projected FH < 8,000FH)

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Structural Prognostics and Health Management (SPHM)

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High Fatigue Usage Anomaly Report (Example Only)

ENABLES BOTH AUTOMATIC & INTERACTIVE ANALYSIS OF AIRCRAFT DISPLAYING HIGH FATIGUE LIFE EXPENDITURE Aircraft displaying severe FLE highlighted RED.

Click to view structural usage history of aircraft

FLE history can be viewed by clicking and selecting:

UAI
Squadron
Fleet

Structural usage history automatically displays RED when usage is significantly more severe than baseline. Detail can be viewed by clicking – see next slide.

Base China Lake Squadron 54 Control Point XX LH Wing, Rear Spar Attach UAI Flight Hours (AFH) Current FLE Current FLE Rate (per 1000FH) Design FLE Rate (per 1000FH) FLE Limit Remaining FLE Projected AFH at FLE Limit Remaining AFH to FLE limit Remaining AFH to 8000FH FLE Flt Hours (AFH) Date xx001 985 0.22 0.22 0.125 1.00 0.78 4477 3492 7015 N/A N/A N/A xz452 1253 0.16 0.13 0.125 1.00 0.84 7831 6578 6747 N/A N/A N/A xx236 1350 0.30 0.22 0.106 0.85 0.55 3825 2475 6650 0.85 3825 Mar-21 xx540 2765 0.35 0.13 0.125 1.00 0.65 7900 5135 5235 N/A N/A N/A xz400 1520 0.10 0.07 0.125 1.00 0.90 15200 13680 6480 N/A N/A N/A Description Projected Inspection Point (click to enter detail - default=25 FH/Month)

AIRCRAFT FATIGUE - ANOMALY REPORT UAI Current FLE Rate (per 1000FH) Design FLE Rate (per 1000FH) xx236 0.22 0.106 FLE History View FLE History Structural Usage History Sortie Patterns - Mission Utilisation Sortie Patterns - Stores Configuration Sortie Patterns - Flying Hours Landing Gear Usage Load Factor Exceedances Flight Envelope Usage - Mach-Altitude Flight Envelope Usage - Time at Buffet Cockpit Pressurisations Door Openings Speed Brake Usage Control Surface Manoeuvres

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Structural Prognostics and Health Management (SPHM)

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High Fatigue Usage Anomaly Report (Example Only)

FLE History - xx236 (CP XX) 0.1 0.2 0.3 0.4 0.5 0.6 200 400 600 800 1000 1200 1400 FH FLE FLE FLE Rate/1000FH

AIRCRAFT FATIGUE - ANOMALY REPORT UAI Current FLE Rate (per 1000FH) Design FLE Rate (per 1000FH) xx236 0.22 0.106 View FLE History Structural Usage History Door Openings Speed Brake Usage Control Surface Manoeuvres Sortie Patterns - Mission Utilisation Sortie Patterns - Stores Configuration Sortie Patterns - Flying Hours Landing Gear Usage Load Factor Exceedances Flight Envelope Usage - Mach-Altitude Flight Envelope Usage - Time at Buffet Cockpit Pressurisations

ENABLES BOTH AUTOMATIC & INTERACTIVE ANALYSIS OF AIRCRAFT DISPLAYING HIGH FATIGUE LIFE EXPENDITURE

FLE vs Flight Hours - Squadron Overview

0.05 0.1 0.15 0.2 0.25 0.3 500 1000 1500 2000 2500 Flight Hours FLE Sqn 411 Sqn 54 Linear (Sqn 54) Linear (Sqn 411)

Design FLE Rate Sqn 54 FLE Rate Sqn 41 FLE Rate

Can compare FLE vs. Flight Hours or vs. Landings for different squadrons to provide a comparison. Individual Aircraft FLE History : Highlights any significant changes in the FLE rate

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Structural Prognostics and Health Management (SPHM)

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Predicted Maintenance Screen (Example Only)

Filter by Aircraft Tail Number Again, could be either:

all monitored control

points

top 20 (for example)
control points due for

inspection in next 1/3/6/12 month period DETAILS CONTROL POINTS ON AN INDIVIDUAL AIRCRAFT BASIS AND PROJECTED MAINTENANCE DATES Remaining Flight Hours to Maintenance shown – could list in descending order or highlight those with less than 100 / 50 hours remaining

Aircraft Tail No. Variant Entry Into Service Date

No. of Flts

Flight Hours (AFH) XX001 CTOL Jul-14 4365 6548 Control Point No. Control Point Description Date Flaw Size AFH Remaining AFH Date 0029 LH Wing, Rear Spar, N/A N/A 6750 202 Nov-41 0133 LH HT Spar 1 I/B, Rib 4 shear joint N/A N/A 8900 2352 Jul-49 0008 VT Aft root rib, fairing web attachment N/A N/A 7300 752 Sep-43 0268 RH Wing Leading Edge Upper Flange BL175 N/A N/A 6630 82 Feb-40 Sortie Info Summary Control Point Summary Previous Maintenance Predicted Maintenance

Predicted Maintenance point is calculated automatically based on the flaw size projections – however capability should exist for manual entry as a result

f in-service

arisings.

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Structural Prognostics and Health Management (SPHM)

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Actual vs. Baseline Comparison Data Example

CTOL Mission Utilisation - Actual vs. Design Comparison

5 10 15 20 25 30 ACM BFM ACT GUN TI RAS BSA BSA CAS SAT SAT DI Mission Type Mission Utilisation (%) Design Mission Utilisation (%) Actual Mission Utilisation (%)

Actual / Design Comparison (%) 20 40 60 80 100 120 140 160 FS Landings Conventional T/Os Touch & Go's Gear Extensions (In-Flight) Gear Extensions (Gnd) Event Actual / Design (% )

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Structural Prognostics and Health Management (SPHM)

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Structural Event Monitoring

Maintainer interface will specify exact tasks to be accomplished to verify structural integrity Flight recreation visualization aids understanding of damaging maneuvers

Parameter recording and display available for engineering analysis

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Structural Prognostics and Health Management (SPHM)

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Force Life Management Capability

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Structural Prognostics and Health Management (SPHM)

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Corrosion Model Concept

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Structural Prognostics and Health Management (SPHM)

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Off Board Tools

Assess Material Condition
Anomaly and Failure Resolution System
Knowledge Discovery
Force Life Management

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Structural Prognostics and Health Management (SPHM)

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Future Technologies

Crack detection and monitoring

– CVM, MWM technologies

Structural Integrity Prognosis System (SIPS)
Airframe Reliability and Risk Assessment

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Structural Prognostics and Health Management (SPHM)

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VSPHM MSPHM AVPHM MS VS OBPHM R&M Struct Aero Integrity FTI Maint PHAM u/cPHM GTI Manuf S/W SPHM

IPT Interaction

SLIDE 61

Questions?

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