The Aerospace Industry Steering Committee on Structural Health Monitoring and Management (AISC-SHM): Progress on SHM guidelines for aerospace.

Transcription

1 The Aerospace Industry Steering Committee on Structural Health Monitoring and Management (AISC-SHM): Progress on SHM guidelines for aerospace. Peter Foote, BAE Systems Grant Gordon, Honeywell Mark Derriso, AFRL Presented by Peter Foote International Workshop on Structural Health Monitoring, Stanford University, 2011

2 Contents Motivation of AISC-SHM Background Interaction with ATA MSG-3 Summary and challenges to the industry

3 Vision and Motivation of AISC-SHM The AISC SHM is an international team comprising industry, government and academic participants with a collective vision to efficiently and effectively implement structural health monitoring for a wide variety of commercial and military aerospace applications through the development of guidelines, procedures, processes and standards for implementation and certification of the technologies. The AISC-SHM operates as a Technical Committee within SAE Aerospace (an SAE International Group) within the Aerospace Division (G-11 SHM)

4 Provenance 3 rd EWSHM 2006 in Granada: Call from industry for an international community of practice Professor Fu-Kuo Chang, Stanford University launches AISC-SHM in Stanford, Sept 2006 Commercial Aviation Working Group formed 2007 Military Aerospace working group formed AISC-SHM joins SAE Aerospace as a new technical document committee 2008 First meeting as an SAE Committee (G-11 SHM), - London Jan 2009

5 Provenance Granada 3 rd EWSHM: Call from industry for an international community of practice Professor Fu-Kuo Chang, Stanford University founds AISC-SHM in Stanford, Sept 2006 Commercial Aviation Working Group formed 2007 Military Aerospace working group formed 2008 AISC-SHM joins SAE Aerospace as a new technical document committee 2008 First meeting as an SAE Committee (AMS-S), London Jan 2009 Stanford 2006

6 The committee focus is development of aerospace industry guidelines for structural health monitoring to achieve: Cross industry consensus on SHM implementation issues. Basis for SHM systems certification by providing the necessary guidelines (e.g. SAE ARP). Identification of technology gaps. Interface with other activities pertaining to aeronautical SHM Collective view among various organizations such as: OEMs: aircraft manufacturers Regulatory Authorities System Integrators Developers / Research organizations Operators and their representatives

7 AISC-SHM membership Platform OEMs System Integrators Research Organizations Regulators Operators 6 Regulatory Agencies 5 Aircraft / Fleet Level Integration & Processes 3 System Integration 1 2 Research Institutes System Developer Airbus (EADS) AFRL BAE Systems Boeing Bombardier EASA Embraer FAA FHI GE Honeywell NASA NAVSEA RIMCOF Sandia Stanford Uni. Univ. of Tokyo

8 AISC-SHM mission The mission of the AISC-SHM is to provide an approach for standardizing integration and certification requirements for SHM of aerospace structures, which will include system maturation, maintenance, supportability, upgrades and expansion. The goal is to develop a guidebook specifying approaches for SHM usage on Air and Space vehicles and to identify technology gaps leading to SHM utilization.

9 Organization and Responsibilities AISC-SHM: AISC -SHM Aerospace Industry Steering Committee for Structural Health Monitoring toring. Committee structure AISC-SHM Main Technical Committee. Operators / end users, Regulatory agencies, OEMs, Systems integrators and SHM Suppliers, Research organisations / institutions, other interested parties. AISC-SHM Executive Management Board (EMB) Officers, industry/ institutional representatives, chairs of working groups, plus SAE representative. ATA / interaction IATA input SAE Administration Working Groups CAWG SAE SHM Guidebook task MAWG Future groups CAWG Commercial Aviation Working Group MAWG Military Aviation Working Group Current Chairmen: AISC-SHM Peter Foote, BAE Systems CAWG and SAE Document sponsor: Grant Gordon, Honeywell MAWG: Mark Derriso US Air Force The committee is also known as G-11 SHM within the SAE International Aerospace Division

10 Creation of an SAE International, Aerospace Recommended Practices Document on the implementation of SHM for aerospace.

11 Guidelines contents Scope (air vehicle, air frame, structural components) Applicable documents (existing standards, related guidelines etc) Background (context of SHM in aircraft support processes and structural design philosophies, overview of technologies) Introduction to SHM systems. (Functional elements of structural health management systems based on condition and usage monitoring techniques) Fields of application (How SHM can be used, intended function, concepts of operation) SHM system requirements (What must SHM systems and techniques do) Qualification V&V Certification How to assure that chosen SHM solutions meet functional, operational and regulatory requirements Military annex (differentiation of military and civil implementation)

12 Division of effort Team (alphabetic): Airbus (EADS), AFRL,BAE Systems, Boeing, Bombardier, Embraer FHI, Hahn Spring, Honeywell, NASA, NAVSEA, RIMCOF, Sandia, Stanford Uni., Univ. of Tokyo Section Lead Scope Applicable documents Background Introduction to SHM systems Fields of application SHM system requirements Qualification V&V Certification Military annex Boeing Honeywell Boeing BAE Systems Airbus and Boeing Airbus Hahn Spring (Consultant) and Sandia plus team AFRL

13 Illustrative work in progress Certification: tasks to obtain approval for [5] Design Production Installation Instruction [6] for Continued Airworthiness Intended functions [0] and function use cases Syst em [2] Development Syst em [3] Product ion Syst em [4] Installation Syst em [7] Utilisation Maturation [1] Benefit/ Credit [8] Validation Figure 1(a): Evolution and certification of SHM systems, a simplified diagram Expected Organisation [0] any [1] any [2] S, O, A [3] S, O, A [4] S, O, A [5] R, S, O, A [6] R, S [7] O [8] O, S, R, A, T Regulator: R (FAA, DOD, MOD) Aircraft manufacturer: A SHM system manufacturer: S Operator: O Technology developer: T (small companies/academia)

14 Illustrative work in progress.. Certification phases through Project Specific Certification Plan [5] Conceptual Requirements Compliance Implementation Post design definition planning certification Instruction [6] for Continued Airworthiness Intended functions: [0] Det ect, monitor and/ or assess accidental/environmental/fatigue damage or damaging events such as overloads and over-speed. Monitor and/ or assess fatigue, usage, loads, and/or structures integrated with SHM to reduce weight, revise safety factors, use new materials, et.. Function use cases: Advisory, Maintenance benefit/ credit Operational benefit/credit Design benefit/ credit Maturation [1] Benefit/ credit evaluat ion algorithm validation, finite element analysis, simple structure tests, complex structure tests, flight tests, Validation evidence System Development [2] Syst em requirement s Functional requirements, and designer, integrator, and operator requirements Determine criticality Safety Assessments, FMECA, Functional Hazard Analysis, Illustrative work in progress Int egrit y requirement s Requirements for software, environmental tests, Syst em Designs Test & Evaluation System Integration Test & Evaluation Flight tests Validation evidence Tests may be required not only for SHM but also for structural items and may cover: coupon tests, environmental tests, full scale tests, static tests, durability tests, etc. Syst em [3] Product ion Syst em [4] Installation Syst em [7] Utilisation Benefit/ Credit [8] Validation Figure 1(b): Evolution and certification of SHM systems, an explanatory diagram

15 Illustrative work in progress.. Certification phases through Project Specific Certification Plan [5] Conceptual Requirements Compliance Implementation Post design definition planning certification Instruction [6] for Continued Airworthiness Intended functions: [0] Det ect, monitor and/ or assess accidental/environmental/fatigue damage or damaging events such as overloads and over-speed. Monitor and/ or assess fatigue, usage, loads, and/or structures integrated with SHM to reduce weight, revise safety factors, use new materials, et.. Function use cases: Advisory, Maintenance benefit/ credit Operational benefit/credit Design benefit/ credit Maturation [1] Benefit/ credit evaluat ion algorithm validation, finite element analysis, simple structure tests, complex structure tests, flight tests, Validation evidence System Development [2] Syst em requirement s Functional requirements, and designer, integrator, and operator requirements Determine criticality Safety Assessments, FMECA, Functional Hazard Analysis, Illustrative work in progress Int egrit y requirement s Requirements for software, environmental tests, Syst em Designs Test & Evaluation System Integration Test & Evaluation Flight tests Validation evidence Tests may be required not only for SHM but also for structural items and may cover: coupon tests, environmental tests, full scale tests, static tests, durability tests, etc. Syst em [3] Product ion Syst em [4] Installation The major benefits Syst em [7] Utilisation Benefit/ Credit [8] Validation Figure 1(b): Evolution and certification of SHM systems, an explanatory diagram

16 Working definitions and examples of credits / benefits The maintenance credit/benefit functions achieve specific improved maintenance tasks that can replace existing tasks or can be considered as Alternative Means of Compliance (AMOC) to existing inspection tasks. Examples of such tasks are (a) detect a falsely reported hard-landing event and eliminate the inspection required after the event, (b) detect structural damage at fixed scheduled intervals (S-SHM), (c) indicate need/opportunity to change maintenance planning (turning unscheduled into scheduled maintenance) etc.

17 Working definitions and examples of credits / benefits The maintenance credit/benefit functions achieve specific improved maintenance tasks that can replace existing tasks or can be considered as Alternative Means of Compliance (AMOC) to existing inspection tasks. Examples of such tasks are (a) detect a falsely reported hard-landing event and eliminate the inspection required after the event, (b) detect structural damage at fixed scheduled intervals (S-SHM), (c) indicate need/opportunity to change maintenance planning (turning unscheduled into scheduled maintenance) etc. The operational credit/benefit functions achieve improved operational, management and structural integrity tasks that can replace existing tasks or can result in maintenance planning benefits as increasing inspection intervals. For example, load and fatigue monitoring functions can be used to adjust scheduled task intervals or trigger crack inspection tasks.

18 Working definitions and examples of credits / benefits The maintenance credit/benefit functions achieve specific improved maintenance tasks that can replace existing tasks or can be considered as Alternative Means of Compliance (AMOC) to existing inspection tasks. Examples of such tasks are (a) detect a falsely reported hard-landing event and eliminate the inspection required after the event, (b) detect structural damage at fixed scheduled intervals (S-SHM), (c) indicate need/opportunity to change maintenance planning (turning unscheduled into scheduled maintenance) etc. The operational credit/benefit functions achieve improved operational, management and structural integrity tasks that can replace existing tasks or can result in maintenance planning benefits as increasing inspection intervals. For example, load and fatigue monitoring functions can be used to adjust scheduled task intervals or trigger crack inspection tasks. The design credit will be sought to underwrite new designs and materials.

19 Interaction with ATA MSG-3

20 Courtesy ATA and Lorenz Wenk, Airbus

21 MSG-3 SHM revision history ATA SHM Working Group activity kick off meeting Established initial revision proposal for S-SHM September 12-13, 2007 Stanford, CA Maintenance Programs Industry Group (MPIG) Meeting Defined Industry accepted methodology January 8-10, 2008 Memphis, TN International MRB Policy Board Meeting Requested further review of detailed MSG-3 structure procedure steps April 22-25, 2008 Cologne, Germany initial loop ATA SHM Working Group meeting Developed further detailed S-SHM revision proposal and initial P/C- SHM principles September 16-18, 2008 Hamburg, Germany Maintenance Programs Industry Group (MPIG) Meeting Concluded on proposed further S-SHM methodology November 18-20, 2008 Washington, DC International MRB Policy Board Meeting Reviewed and accepted final S-SHM revision proposal March 31- April 3, 2009 Sao Jose dos Campos, Brazil MSG-3 Revision Approval second loop ATA SHM Working Group meeting Develop further revision proposal for scheduled task adjustments & replacements by SHM Sep. 29-Oct. 1, 2009 Toronto, Canada Maintenance Programs Industry Group (MPIG) Meeting Concluded on proposed further SHM methodology November 3-5, 2009 Bordeaux, France International MRB Policy Board Meeting Reviewed further SHM revision proposal March 31- April 3, 2009 Singapore IP 105 Approval third loop Courtesy ATA and Lorenz Wenk, Airbus

22 Working definitions and examples of credits / benefits Embodied in MSG-3 IP The maintenance credit/benefit functions achieve specific improved maintenance tasks that can replace existing tasks or can be considered as Alternative Means of Compliance (AMOC) to existing inspection tasks. Examples of such tasks are (a) detect a falsely reported hard-landing event and eliminate the inspection required after the event, (b) detect structural damage at fixed scheduled intervals (S-SHM), (c) indicate need/opportunity to change maintenance planning (turning unscheduled into scheduled maintenance) etc. The operational credit/benefit functions achieve improved operational, management and structural integrity tasks that can replace existing tasks or can result in maintenance planning benefits as increasing inspection intervals. For example, load and fatigue monitoring functions can be used to adjust scheduled task intervals or trigger crack inspection tasks. The design credit will be sought to underwrite new designs and materials.

23 SHM in MSG-3 revision An S-SHM task: would be a generic AMM task procedure without Non- Destructive Test Method (NTM) can be carried out with aircraft type rating without additional training uses technology with built in go/no-go determination capability significantly reduces human factors The fixed interval avoids operational issues! No unplanned operational interruptions Safe operation within the interval scope per definition Potential SHM technology failure will be evident when performing the task Courtesy ATA and Lorenz Wenk, Airbus

24 Working definitions and examples of credits / benefits The maintenance credit/benefit functions achieve specific improved maintenance tasks that can replace existing tasks or can be considered as Alternative Means of Compliance (AMOC) to existing inspection tasks. Examples of such tasks are (a) detect a falsely reported hard-landing event and eliminate the inspection required after the event, (b) detect structural damage at fixed scheduled intervals (S-SHM), (c) indicate need/opportunity to change maintenance planning (turning unscheduled into scheduled maintenance) etc. The operational credit/benefit functions achieve improved operational, management and structural integrity tasks that can replace existing tasks or can result in maintenance planning benefits as increasing inspection intervals. For example, load and fatigue monitoring functions can be used to adjust scheduled task intervals or trigger crack inspection tasks. The design credit will be sought to underwrite new designs and materials. Aspiration and logical end goal for SHM to fully utilize its capability.ip 105

25 SHM in MSG-3 IP105 SHM Operation Mode Scheduled SHM (S-SHM) from IP92, no change Automated SHM - SHM technology which does not have a pre-determined interval at which maintenance action much takes place, but instead relies on the system to inform maintenance personnel that action must take place SHM Technology Type Damage Monitoring System SHM technology that uses sensors to directly monitor structure for deterioration conditions Operation Monitoring System SHM technology that uses sensors which do not directly check the structure for damage, but instead correlate various measurements (e.g. environment conditions, loads) to make an inference to the probability or likelihood of damage Courtesy ATA and Lorenz Wenk, Airbus

26 SHM in MSG-3 IP105 Principle SHM evaluation procedure scheduled operation mode? automated operation monitoring technology type? damage monitoring scheduled SHM task MSG-3 rev NO classic scheduled inspection task IP 105 classic inspection can be adjusted by SHM? YES Courtesy ATA and Lorenz Wenk, Airbus NO adjusted scheduled inspection task SHM covers classic inspection requirement s YES? no task

27 Automated SHM allows true CBM Point where degradation starts System detection limit Performance System notifies maintainer Maintenance planning window Operational limit if safety critical Failure Safety margin Time Trend monitoring and RUL calculation

28 In Summary The AISC-SHM is preparing SAE International Aerosapce Recommended Practices guidelines for the implementation of SHM for aerospace application Target date for publication 2012 The group draws on a wide range of OEMs, integrators, regulators and technology providers The AISC overlaps with the ATA MSG-3 revision process via the ATA MSG-3 SHM Working Group Successful revisions and Issue Papers from the ATA working group will be reflected in the AISC guidelines.

29 Challenge to the industry Issue guidelines for implementation of SHM using wide consultation with industry, regulator and user communities. OEMs, Technology Developers and suppliers must join efforts to present real S-SHM and A-SHM applications proposals to Regulatory Authorities in the next couple of years: only this will convince all stakeholders of the value of SHM.

30 Contacts and links AISC-SHM Committee chairman: Peter Foote Guidelines document sponsor and Chair of Commercial Aviation Working Group: Grant Gordon Chair of Military Aviation Working Group: Mark Derriso

31 Acknowledgements SAE International The Air Transport Association Members of SAE Aerospace Technical Committee G-11 SHM ATA MSG-3 SHM working group

32 Public Hearing 11:20 Room HC (Basement meeting room) Informal Q&A / discussion on guidelines with members of the AISC-SHM team.