Moving the Industry Forward with Structural Health ......2017/09/20 · • SAE Committee’s...

Delta TechOps | September 20, 2017 |

Moving the Industry Forward with Structural Health Management

(SHM)

Sept 20, 2017

David Piotrowski Delta TechOps – Senior Principal Engineer

ASNT Level III – UT, ET, PT

Delta TechOps | September 20, 2017 | 2

Outline

• Delta/FAA/Boeing/SMS/AEM programo What next?

• FAA Mtg Nov 2016– Unified Approach– No barriers/regulatory issues to move fwd with ‘hot spot’ applications

• Active vs Passive; Global vs local

• SAE Committee’s – IVHM & SHM o Guidance documents o AIR 6900 o Validation & Verification – ARP 6461, ARP 6887o POD, reliabilityo Mtc Credits

• FAA Test on Composites

• Big Data and Predictive Analyticso Boeing/Airbus/Embraero ‘The Hangar’

• Misc. innovative steps


This is NDT, we’re not SHM (?)• NDT vs Visual argument

– 80-90% of inspection is visual

• SHM Standard development occurring now (SAE Committees)o Opportunity to shape training reqts, deployment details,

monitoring procedures

• “Direct reading” – no interpretation, so no NDT requirements

• Front-end program development (i.e., where to install, which sensor to install, how to install), software algorithm development, etc., may determine POD

• NDT Level IIIs (and Level IIs) can ‘adopt’ SHM o Perfect opportunity to use NDT skillseto Knowledge of many techniques (Acoustic emission, UT Waves, ET

sensors, piezos)o Knowledge of structure, Engineering teams

o Knowledge of operations, front front-line to back shops

Step-up to ownership or you will be bypassed


• Vision for SHM usage at Delta

― Initially: alternate inspections of difficult to access areas.

• Inconvenient MTC visits.

• Hotspot monitoring – AMOCs.

― Medium term:

• Early warning of issues; Escalations

― Future: Condition Based MT & Crack Monitoring.

• ‘Smart Signal’ for engines.

• OEM Support.

• Two main hurdles to implementation.

― Business Cases (payback).

― Lack of regulatory guidance, education.

• Solution: FAA program with Delta for SHM implementation.

― Delta writes the guidance/blueprint for SHM certification.

• HM-1 & AISC-SHM SAE Committees => ARP 6461

Operator perspective - SHM

SHM is next level of NDT


737NG application selected for FAA program


B737 NDT Manual Incorporation


SB Modification/Revision


Industry accolades

Time to ‘harvest the benefits’


Next Steps

• Part 1: S-SHM for ‘alternate inspection approvals’o “Hot spot monitoring”o Perform SHM reading at same scheduled interval (S-SHM)

Avoiding open-up = Cost Savings!

Ready for additional applications!


Additional Applications

Embraer charging ahead


What’s next for SHM?• Technology ready, philosophy is not

– Industry education, awareness– MSG3 documents => ‘NDT’ replaced with ‘NDT/SHM’– NDT, SHM not in CFRs (and should not be)– Easier acceptance when Industry Stds (ARP 6461) are utilized

3 parts envisioned on operator end:

• Part 1: S-SHM for ‘alternate inspection approvals’– “Hot spot monitoring”– Perform SHM reading at same scheduled interval (S-SHM)

• Part 2: Blend of S-SHM and ‘predictive/prognostics’– Early warning system (Proactive mtc.)– Extension of intervals (escalation)

• Part 3: ‘Condition based maintenance’ – Philosophy shift to allow ‘monitoring’ or CBM; heavy OEM involvement– AD 2007-10-04/SB MD80-55A065 AMOC – Monitoring stop drilled holes

• Speed is dependent upon OEM and FAA ‘side-by-side’ timeframe.– Get comfortable with new technology/philosophy– Operator pay-back, financials directly dependent upon this!

Seismic philosophy shift coming


Joint viewpoint to FAA

Much persuasion needed for full potential of SHM

OEM led or partnered!


(Source: I. Jennions, Cranfield Univ)

SHM can fit into F&DT Philosophy

Must speak the F&DT language

Delta TechOps | September 20, 2017 |

AHM Adoption in MSG-3

- Update for IMRBPB from MPIG

AHM WG -

IMRBPB MeetingCologne, April 2017

Presented by:Dragos Budeanu - IATAMPIG AHM WG Secretary


Larger view – Health Management

SHM is a segment of overall IVHM


• Integrated Vehicle Health Management (IVHM) Steering Group

Responsible for:

IVHM SG

Take it to a higher level


Several Committees under IVHM

Bring SAE leadership into education, persuasion efforts with regulators


IVHM Hierarchy

Documents issued or drafted to meet need

Many documents exist or in draft


IVHM Capability Levels

JA6268: "Design & Online Information Exchange Standard for Health-Ready Components," includes harmonized classification system and supporting definitions that:

• Identify six levels of IVHM system capability from essentially “no automation” to “self-adaptive health management”.• Base definitions and levels on functional aspects of technology.• Describe categorical distinctions for a step-wise progression through the levels.• Are consistent with current industry practice and future directions.• Eliminate confusion and are useful across numerous disciplines (engineering, legal, media, and public discourse).• Educate a wider community by clarifying for each level what role maintenance technicians have in performing vehicle repairs.


JA6268: "Design & Online Information Exchange Standard for Health-Ready Components."

IVHM Capability Levels


AIR 6900 Drafted, Balloted

SAE Aerospace Standard Types

AS Aerospace Standards – specific performance requirements used for design standards, parts standards, minimum performance standards, quality and other areas conforming to broadly accepted engineering practices or specs for a material, product, process, procedure or test method

ARP Aerospace Recommended Practices – documentations of practice, procedures, and technology that are intended as guides to standard engineering practices. May be of a more general nature or propound data that have not yet gained broad acceptance.

AIR Aerospace Information Reports –compilations of engineering reference data, historical information, or educational material useful to the technical community

Need to push this from AIR to ARP to AS!


Must engage, educate regulators

Regulators are key stakeholders!

• AISC-SHM Committee Efforts expandedo Use IVHM other committees for increased exposure

• ANAC – Embraer efforts

• IATA, A4A MPIG group

• Data-driven & enhancement to safety

• FAA = safety. Which is a safer philosophy?o #1 Corrosion found at Heavy Check

Area only opened once every 3 years Onerous access, Visual Insp Damage extensive, Skin panel replacement by the time damage is found Possible AD?

o #2 SHM system Data taken monthly (or even daily) 3 months after check = notice an issue Ability to ‘monitor’ until can examine at next convenient opportunity Unscheduled mtc can become scheduled mtc Clean-up corrosion, apply CIC at next convenient visit Apply new knowledge to rest of fleet (proactive instead of reactive)


Proposed Roadmap G-11

May-17

2015 2016 2017 2018 2019 2020 2021 2022

Detection Capability-Reliability

Application Case #1 Priority

Scheduled Maintenance vs Conditioned Based Maintenance

- Get rid of unscheduled maintenance

Diagnostics

Prognostics

Algorithms

Software

S-SHM (scheduled)

A-SHM (automated)

Area Inspection FAA joint programs

Damage sizing vs detection vs location

Operational Monitoring-Fatigue, Exceedance, Environmental

Certification (More complex systems)

Maintenance Credit

Maintainability

Standardization of the quality of sensors

Review and use HM-1 Stds

Short term range-MSG-3 allows SHM use

Medium range-Flying with cracks/CBM

Long range-Design changes due to SHM use

AISC-SHM Road Map

Let’s execute and compress road map!

Change ‘find it, fix it’

philosophy!


• FAA research SHM research program with Boeing, Delta, AANC, SMS

and AEM using CVM completed

• Provided recommendations to revising ARP 6461 based on FAA program

• Area that needs some work:

o Operator involvement/maintenance program

o Reliability/POD

o Interface with regulatory agencies

• IVHM Document ARP 6887 started – Validation & Verification

• E-32, ARP5987 (Maintenance Credits) work continues.

o Engine OEMs have been working it from scratch for one year.

o Around 70% complete.

ARP 6461 Revision/ ARP 6887

‘Maintenance Credits’ is large goal, asap


POD/Reliability?

• AISC-SHM working on document for Reliability of SHM

• Different from Validation/verification

• Incorporate SHM into HUMS

o HUMS based decision making process

o AC29-2C (HUMS)

• AIR 6245: SHM for Military Aircraft

o MIL-STD-1530 & SHM

Rotorcraft & Military SHM Working Groups

Reliability document in progress


Active/Passive; Local/Global

• Passive = Only takes data when prompted on the ground by Mtco Delta 737 Program

• Active = Taking data in-flight; Can use ACARS to send data proactively to Mtco Structures vs systems/components

• Local = Specific location, looking for already ‘defined’ damageo Delta 737 Programo Typically MPD, SB or AD

• Global = Wide area, looking forany anomalyo Nervous System

• Unique challenges to each!

• FAA is ok with Local, PassiveSystems; not so with Global or active yet

(Source: H. Specmann en R. Henrich, Airbus)

Recommend separating active/passive, local/global


FAA Fatigue Platform- FAA Assessment of Emerging Technology Advanced Metallic Fuselage Structure- First test in June, second in January, 3 months each, 7 panels total- 10x6’ parts with 2500 cycles/wk- Using Acellent sensors, open to introducing others at no-cost basis

FAA Fatigue Test using SHM

(Source: FAA)


Big Data & Analytics

(Source: Boeing)

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwjum5zK7Y7WAhUJYiYKHcrDBgoQjRwIBw&url=http://tweetiz.com/rupaharia/&psig=AFQjCNFVK9Bj_pqSoIMydra_Qt5l4s8wAA&ust=1504728598387602http://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwjum5zK7Y7WAhUJYiYKHcrDBgoQjRwIBw&url=http://tweetiz.com/rupaharia/&psig=AFQjCNFVK9Bj_pqSoIMydra_Qt5l4s8wAA&ust=1504728598387602


Big Data & Analytics


OEMs Moving into MRO/Partnering


Delta & GT – “The Hangar”


Delta’s Predictive Mtc Group

• Through downlinked real time data and the use of predictive modeling, Delta is able to move from unscheduled maintenance events to scheduled maintenance events

• Dedicated Team (Engineers, AMTs)

o Partner with OEMs on some solutionso Boeing AHMo Airbus PRM

• Delta engineered solutions o Instrumentation and downlinking of data on aircraft

systems/components which do not have an OEM prognostic solution

o 737 ECS Patent


Predictive Benefits

~1000 potential delays, cancellations, ODI’s Mitigated in past 12 months!

0

10

20

30

40

50

60

70

80

90

Potential Delay Prevented Potential ODI Prevented Potential Cancellation Prevented Potential AOS Reduced


Misc. Innovative Steps

• SHM with RFID tags

• Wireless Sensors

• Energy Harvesting

• More Active systems

• Global Systems

• Artificial Intelligence

https://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwiyue245Y7WAhWB6SYKHfPDA0kQjRwIBw&url=https://revealgrowth.com/accelerate-innovation-success/&psig=AFQjCNEVxeed2tUG5c_wRBC0csQAIoLAUw&ust=1504726474595090https://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwiyue245Y7WAhWB6SYKHfPDA0kQjRwIBw&url=https://revealgrowth.com/accelerate-innovation-success/&psig=AFQjCNEVxeed2tUG5c_wRBC0csQAIoLAUw&ust=1504726474595090


Summary

• SHM available for ‘hot spot’ usageo SBs and AMOCso Inconvenient Mtc Intervals (costly open-up)o Operators/MROs can assist

• SAE Committee Worko ARP 6461 Revisiono Maintenance Credits

• Big Data impact on Mtc

• OEMs moving into Mtc via SHM

• $$$$ will drive SHM to reality

Moving the Industry Forward with Structural Health ......2017/09/20 · • SAE Committee’s...

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