Mr. Andy Hess JSF PO PHM Development Leads The Cornerstone of Prognostics and Health Management: The...

Mr. Andy Hess

JSF PO PHM Development Leads

Prognostics and Health Management: The Cornerstone ofThe Cornerstone of

Autonomic LogisticsAutonomic Logistics

‘Joint Strike Fighter,’ ‘JSF,’ and the JSF Logo are Trademarks of the United States Government.

Approved for public release

BE THE MODEL ACQUISITION PROGRAM FOR JOINT SERVICE AND INTERNATIONAL

COOPERATION

DEVELOP AND PRODUCE AN AFFORDABLE NEXT GENERATION STRIKE FIGHTER WEAPON SYSTEM

AND SUSTAIN IT WORLDWIDE

VISION



Current Logistics Structure

Too Large & CostlyToo Large & Costly


P

HM

Key Elements of Autonomic Logistics

JDIS

Tec

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nab

led

War

fig

hte

r

Autonomic LogisticsAutonomic Logistics

Affordable, Survivable, Maintainable, SupportableAffordable, Survivable, Maintainable, Supportable

Logistics InfrastructureLogistics Infrastructure

Operationally Available and Lethal


Autonomic Logistics Structure

Integrated Supply/

EngineeringInfo systems

Service/IndustrySupport Organization

Lessons Learned/

Failure Rates

Industry

Wholesale Stockpoint

Automated Logistics Update

Automatic/JIT Re-Supply

Supply of AOG item/ Replenishment of Ship Stock

Return of Defective Item

Aircraft Available

Aircraft Turn-round & Repair

Prognostics &

Diagnostics Download

Operational Requirements Repair

Required

Replenishable Requirements

High SGRHigh SGR

OnboardStock

Repair Recommendation

Audio

Simulated World

GraphicalHaptic

Maintenance Rehearsal

Intelligent Air Vehicle

PHM


Prognostics and Health Management

What is it?• Diagnostics – is the process of determining the state

of a component to perform its function(s)

• Prognostics – is predictive diagnostics which includes determining the remaining life or time span of proper operation of a component

• Health Management – is the capability to make appropriate decisions about maintenance actions based on diagnostics/prognostics information, available resources and operational demand.

PHM turns ‘Bad Actors’ or ‘Intermittents’ into scheduled maintenance without affecting the success of the Mission


Goals of PHM

• Enhance Mission Reliability and Aircraft Safety• Reduce Maintenance Manpower, Spares, and Repair

Costs• Eliminate Scheduled Inspections• Maximize Lead Time For Maintenance and Parts

Procurement• Automatically Isolate Faults to 1 LRC• Eliminate CNDs and RTOKs• Provide Real Time Notification of an Upcoming

Maintenance Event at all Levels of the JSF Logistics Chain


PHM Vision

PHM System

Tech Integration

Tech Investigation

Oil Flow

)

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±

±

±

±

±

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±

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Tech MaturationThrough Tests,

Demo’s and Workshops


PHM

PHM Maturation Strategy


CDP PHM Accomplishments

• Mature candidate technologies through special tests and programs– SFET, Tech Maturation Efforts, Demonstrations, SBIR’s, IMATE,

CACE, Others….

• PHM is designed into the air vehicle– Designed down to all major subsystems– Architecture is well defined

• PHM req’ts are reflected in JORD and JMS• Req’ts and interface definitions defined• Modeling environments developed• PHM req’ts flowed to subsystem suppliers• PHM maturation plans through E&MD


F100 SEEDED FAULT ENGINE TEST PLAN

COMBUSTOR/HPT EROSION

(EDMS)

#1 BEARING FAILURE(ODM,EODM,EBMVIBES,RLI,SWAN)

#5 BEARING ASSEMBLY FAILURE

(ODM,EODM,EBM,VIBES,RLI,SWAN)

FOD/DOD(AFD,IDMS,EDMS,ECS,

VIBES, RLI,SWAN)

FAN 1st ROTOR TIP/TE CRACKS

(ECS,BVM8X,AFD,IDMS,EDMS,VIBES,RLI,SWAN)

BULK OIL DEGRADATION(OCM, EODM,EBM)

HOT SHUTDOWN & BOWED ROTOR

START ATTEMPT(EDMS,VIBES,

RLI,SWAN)

AUGMENTOR GUTTER FAILURE

(EDMS)

LPT BLADE RUB

(EDMS,VIBESRLI,SWAN)

BULK OIL CONTAMINATION(OCM, EODM, EBM,EBM,ODM)

VAPOR PHASE COKING

(OCM, EODM,EBM)

#1 COMPARTMENT FIRE(OCM, EODM,EBM)

#1 CARBON SEAL FAILURE/CONTAMINATION

(ODM, EODM,OCM, EBM,VIBES,RLI,SWAN)

AUGMENTOR FUEL DISTRIBUTION

VARIATION(EDMS)

purple - primary sensor green - secondary sensor

OVERFLOWING / BLOCKED

FUEL NOZZLE(EDMS,VIBES,

RLI,SWAN)

NOZZLE STATIC

STRUCTURE FAILURE

(PZT)

7/31/98

GEARBOX FAILURE

(VIBES,RLI,SWAN)


PHM Technologies Evaluated During CDP

Robust LASER Inferometer (RLI)Epoch Engineering

Stress Wave Analysis (SWAN)

DME

Piezoceramic Patch Crack Detection (PZT)

UTRC

Acoustic FODDetector (AFD)

Oil Flow

F119 Oil DebrisMonitor (ODM)

GasTOPS

Oil Flow

Electrostatic Oil Debris Monitor (EODM)

ExperTech/SHL

Engine Distress Monitoring

System (EDMS)

Ingested Debris Monitoring

System (IDMS)

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Stewart Hughes Ltd

Blade Vibration Meter (BVM8X)

Hood Technology

Electrostatic Bearing Monitor (EBM)

ExperTech

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Oil ConditionMonitor (OCM)

UDRI

Beacon-Based Exception Analysis for Maintenance(BEAM) JPL

Communications Diagnostic Processor

General Purpose Processing

Signal Processing

Signal Conditioning Power Interface/Generation

Sensing Elements Self-calibration/Active Cancellation

ICHM

MEMS Sensors

Eddy CurrentBlade Sensor (ECS)

GDATS


PHM Design Impacts

• PHM Architecture Significantly Improves Performance– Increased fault detection/Fault Isolation– Reduces Ambiguities, Reduce False Alarms, Enables Use of Existing Sensors

• PHM Has Influenced Virtually All Aircraft System Designs– PHM Architecture Design Enables a Comprehensive Approach and Significant Growth Potential – Improve Accuracy & Fault Detection/Fault Isolation, – Incorporated Proven Demonstrated Technologies– Taken Advantage of Existing Parameters and Sensors; Minimal Weight/Cost Impacts– Takes Advantage of Advances in S/W Algorithms and Processing Technology, Reasoners, and a Few

New Sensor Technologies

• PHM Is One of the More Significant Integration Tasks– Enhances the Influence of Supportability Impacts of Design

• Boarded PHM Technologies Have Been Demonstrated, Tested, or Analyzed/Assessed as Low-Risk

• PHM Program Shows Potential For Significant Operational and Support Benefits– Cost Benefit Analyses Defined Very Significant Savings– All Capabilities have to “buy their way on”

PHM Technologies Integrated Into the Design Ensure A Capable, Affordable, Low-Risk Solution


PHM Redefines Design Criteria

• Old– Safety and Supportability are a Function of

Reliability, Redundancy, and the Support Concept ~ Ensures

• New– Safety and Supportability are a Function of

Reliability, Redundancy, PHM Capabilities, and the New Support Concept ~ Drives

Autonomic Logistics Enables a Paradigm Shift Autonomic Logistics Enables a Paradigm Shift


• Reflected in JORD and JMS Requirements• Reaches across the entire airframe

– Mission Systems• FD/FI – In flight reconfiguration

– Structures– Signature– Propulsion

• Dual engine safety with single engine

– VMS• Electronics Prognostics

– Subsystems• Hydraulics• Fuel System• Electric Power System• APU• Drive Shafts• Etc…

PHM is Designed into the Air Vehicle


PHM Architecture

VMS

JDISSafetyMission OpsConfigurations ManagementStatus UpdatesSchedule AdjustmentsGenerate Maintenance ActionsAnalyze Health of Aircraft PopulationProvide IETM KnowledgeTraining Updates

Integ

rate Into

SUBSYSTEMS

MISSION SYSTEMS

LO

STRUCTURES

PROPULSION

N-Area Reasoners

Feed Data for Correlation and

Reporting

AIR VEHICLE

REASONERExisting Aircraft

Parameters

M - Parameters

Minimum Number of Specialized

Sensors

Advanced Algorithms


E&MD Products

• Fully Functional PHM System at Initial Fleet Introduction

• Comprehensive PHM Capability on All Major Subsystems

• Demo’s, Validated and Verified PHM Capabilities• On-board PHM Hardware and Software Architectures

Fully Integrated with the Aircraft Design• Off-Board PHM Seamlessly Integrated with JDIS and

On-Board PHM• Any Appropriate Advanced Technologies Fully

Capable and Prepared for Eventual Insertion at the Proper Time


JOINT DISTRIBUTEDINFORMATION SYSTEM (JDIS)

Maintenance Management• Web Interfaces• Maintainer Identification• Automatic Record of repairs• Compatibility with legacy systems

Database Management• Safety• Mission Ops• Configuration Management• Status Updates• Schedule Adjustments• General Maintenance Actions• Analyze Health of Aircraft• Population• Provide Interactive Electronic Technical Manual (IETM) Knowledge

Communications• Web enabled• Radio Frequency• Infrared/Ultraviolet• SATCOM • Databurst Mayday (Black Box Data)

Intelligent, Connected Logistics Infrastructure

Intelligent, Connected Logistics Infrastructure


ProvideIETM Knowledge

Analyze Health of Airplane Population

Manage Configuration

TAIL NO.

99-006

99-004

99-007

99-011

99-005

99-008

99-009

99-010

99-012

99-013

99-014

99-015

99-016

99-017

99-018

99-019

SE ETIC COMMENTSCONDPRIORITY

Update Status

2343902323439023

FR CODE: 24-20

PREVIOUS ACTION

PMA

TECHNICIAN: D. TremontA/C TAIL NO. TASK/SYSTEM INTERRUPTED

Update

EMPLOYEE NO.: 5581 WUC...

STOP DA

:42EO WORK CENTER: A11AF

TYPE MAINT: BWHEN DISCOVERED: D

UNITS: 0START DATE (YYMMDD): 930520

HOW MAL: 615

CREW SIZE: 0

CORRECTIV

CLOSE

DCN

23439023 A5100 ELECTRICAL Y23439023 A1234 ELECTRICAL N

Generate Maintenance Actions

XXXXX

XXXXXX

XXX

XXXX

Adjust Schedules

JDIS FUNCTIONALITY

F1 FAIL F2 GRAPHIC F3 Quit F4 DFT F5 tbd F6 Menu F7 Back F8 Next

1 F-16 IMIS 2 F-16 IMIS 3 F-16 IMIS 4 F-16 IMIS

Raise panel from fuselage bylifting lower edge first.

Safety

Mission Ops

Intelligent Air VehicleSupply Chain

PHM Component Performance Feedback to OEM’s


Technologically EnabledWarfighter

Interactive Electronic Technical Manuals

On-Line Maintenance Technical Manuals

Maintainer in the Loop

On-Line Support

Technician Enhanced With Technology

ElectronicClassroom

Database

EmbeddedSimulation

Virtual Reality Haptic Feedback

Training ContinuumDistributed Simulation/Mission rehearsal


AUTONOMIC LOGISTICS SUMMARY

By 2020, the JSF will comprise 75% of US Tactical Aircraft

Affordability is the only option

AUTONOMIC LOGISTICS WILL DELIVER


Technologically Enabled Warfighter

Joint Distributed Information System

Autonomic Logistics

PHM

Mr. Andy Hess JSF PO PHM Development Leads The Cornerstone of Prognostics and Health Management: The...

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