Briefing to Aerodays 2011 Parallel session 1G Technologies in the European Research Area. Advanced Structures
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1 Structural Health Monitoring Systems in Airbus Military Briefing to Aerodays 2011 Parallel session 1G Technologies in the European Research Area. Advanced Structures Javier Gómez-Escalonilla Fatigue & Fracture Mechanics Dept.
2 Contents Why Structural Health Monitoring Systems? Structural Health Monitoring System Architecture Artificial Neural Networks Capabilities (Usage-Based Maintenance, Usage+Condition-Based Maintenance)
3 Average fleet age (USAF) Why Structural Health Monitoring Systems? Problem #1: Common increasing requirements to keep the ageing fleets in service even beyond initially established service lives. Fighter/Attack Bomber Tanker Airlift Source: Defence Industry Daily
4 Workload Why Structural Health Monitoring Systems? Problem #2: Frequency of maintenance actions and time to complete drive the operating and support cost of the airframe. New Aircraft Early Mature Stage Late Mature Stage Final Life Stage Fatigue inspection is a minor issue. Limited depot work. Fatigue inspection increasing. Periodic depot visits. Fatigue inspections are major labour cost drivers. Periodic depot visits with increasingly severe emergent repairs. Depots deal with major structural issues. Major Structural Life Assessment Program required to fly due to structural fatigue issues. Total workload Problems fielding deployable units due to smaller population of available airframes. Scheduled workload Unscheduled workload Age
5 Fatigue damage Why Structural Health Monitoring Systems? Problem #3: Real usage of military aircraft shows a significant dispersion: More severe usage than designed Need of more frequent inspections (safety issue) Less severe usage than designed May have less frequent inspections (economic opportunity) Safety issue Economic opportunity Aircraft life
6 Why Structural Health Monitoring Systems? Current solutions: ADVANTAGES TECHNOLOGY DISADVANTAGES No aircraft installation needed CREW FORMS Manual collection of data. Subjective information Simple aircraft installation FATIGUE METERS Applicable to wing root mainly Takes advantage of aircraft flight data PARAMETRIC Limited accuracy High accuracy for fatigue damage estimates STRAIN GAUGES High installation and maintenance costs
7 Structural Health Monitoring System (SHMS) Airbus Military models can be fitted with two structural monitoring systems: Aircraft Condition Monitoring System Short-term structural integrity management (22 aircraft) Structural Health Monitoring System Mid and Long-term structural integrity management (50 aircraft) Aircraft Condition Monitoring System Hard landing detection Load exceedance detection Unscheduled inspections Customized scheduled inspections Aircraft Structural Maintenance Program Structural Health Monitoring System Fatigue damage accrual
8 Structural Health Monitoring System (SHMS) Combination of sensors, data acquisition technology and algorithms with the goals of improving flight safety and reducing life-cycle costs. Scheduled Maintenance Database Flight recorded data Aircraft virtual sensors Signal fault detection Crack initiation analyses SHMS System selfvalidation Sensor error correction Crack growth analyses Structural assessment
9 Structural Health Monitoring System (SHMS) Two main functionalities: Usage Monitoring Function (UMF), Operational Loads Monitoring Function (OLMF). Scheduled Maintenance Database Flight recorded data USAGE MONITORING FUNCTION Assessment of usage patterns of each individual unit of the fleet OPERATIONAL LOADS MONITORING FUNCTION Estimation of accumulated damage of the airframe. Prediction of cracks in the future (quantitative review of the condition of the airframe) Aircraft virtual sensors Fleet management support information Individual aircraft maintenance program evolution
10 Structural Health Monitoring System (SHMS) OLMF based on a dense network of virtual sensors distributed throughout the airframe: Minimum installation and maintenance costs Minimum weight Maximum reliability
11 Structural Health Monitoring System (SHMS) Additional advantages: High flexibility Adaptation to future needs (new maintenance tasks, repairs)
12 Artificial Neural Networks Virtual sensors are based on Artificial Neural Networks (ANNs), algorithms that can learn the underlying mathematical relationship between flight parameters and strains at virtual sensor locations. Flight parameters (time histories) Speed Altitude Weight CoG accelerations etc Strains at virtual sensor (time history) ANNs are trained using information from physical sensors installed in some aircraft of the fleet.
13 Artificial Neural Networks Once trained, the Artificial Neural Networks can reproduce the strains with similar accuracy as a physical sensor. Physical sensor (strain gauge) Virtual sensor (ANN)
14 Capabilities The combination of diagnostic and prognostic capabilities of the SHMS enables the Usage-Based Maintenance (UBM) concept. Diagnosis Impact: Usage assessment Benefit: Improved usage understanding Prognosis Impact: Minimization of incipient failures Benefit: Improved mission reliability Usage-Based Maintenance (UBM) Impact: Customized Scheduled Maintenance Benefit: Tailored Maintenance Time and System Availability
15 Usage-Based Maintenance More severe usage Less severe usage More severe usage Less severe usage Conventional maintenance Usage-based maintenance Same inspections for all aircraft More frequent inspections (safety) Less frequent inspections (economy)
16 Usage+Condition Based Maintenance Future developments: addition of physical inspection sensors and link to logistic support systems to enable the Usage+Condition Based maintenance (U+CBM) concept. Virtual sensors Flight data SHMS NEW Direct link to Logistic Support Management System (LSMS) NEW Physical inspection sensors UBM Could critical locations generate cracks? How are they going to evolve? Why have they appeared? U+CBM Have cracks have been detected? How are they going to evolve? Why have they appeared? Could new cracks appear?
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