Model-Based Integrated Health Management

Transcription

1 Model-Based Integrated Health Management Engineering Resilient Space Systems Keck Institute for Space Studies 2 August 2012 Erv Baumann Integrated Health Management Lead Advanced Programs & Technologies Northrop Grumman Aerospace Systems

2 IHM Operational Elements (for purposes of this presentation IHM = PHM = ISHM = IVHM) Subsystem Control & Health Mgmt Propulsion Vehicle IHM System Provides: AV-Level Info Management Reliable FDIR Prognostics / Trends Supports ALE Fault Management, Reporting & Recording Operator Interface / Mission Control Safety Critical Mission Critical Diagnostic Data Data Terminal MC Displays & Controls & Control Display Unit (CDU). Ground IHM System Avionics Thermal Control Airframe Enabling Technologies Diagnostics & Prognostics Cross-Subsystem FDIR Model-Based Development & Testability Analysis Fault Signature Detection Vehicle HM Fault Codes Flight Data Recorder Fault / Service Info Maintainer Vehicle Interface In-Flight Maintenance Data Link Portable Maintenance Device (PMD) Maintenance Panel IETMs Consumables On-Board Diagnostics Automated Pre- Flight Checkout Support System Automated Operator / Maintainer Debrief Off-Board Prognostics Trending Life Cycle Mgmt Store / Distribute Diagnostic Database DB

3 Objective of Model-Based Diagnostic Design Analysis - Support Design for Maintainability While Reducing Costs Use Model-Based Testability Analysis Tools to Assess Fault Coverage vs. Reqmts Reduce Replication in Related FMECA and Testability Analysis Efforts Support IETM Generation and Informed Maintenance Activities Enable Effective Discrepancy Analysis and Design Updates During Sustainment Reduce Time Required to Develop Variants of Baseline Vehicle Design Architect for Growth Design for Supportability Improve Maintenance & Sustainment

4 Model-Based System Design Enables Performance-Based Logistics Improvements

5 Model-Based System Design and Life Cycle Logistics Loop Inner Sustainment Triangle (Loop) is Executed Many Times Within a Typical Product s Life Cycle Shared System Model Facilitates Timely Life Cycle Support, Block Upgrades, Variant Development, & Configuration Mgmt

6 Model-Based System Development and Sustainment Loop STAKEHOLDER INTERESTS & REQUIREMENT DRIVERS System Analysis Enterprise & Optimization Actual vs Stakeholder Identify areas Predicted in which Performance Teams REQUIREMENTS Engineering Trades Requirements Analysis Impact Analysis REQUIREMENTS CM System Level Requirement Products Segment Level Requirement Products Element Level Requirement Products Subsystem Level Requirement Products REQUIREMENTS IMPORT / EXPORT Reqt Model Reqt Model Reqt Model Reqt Model Functional Models Performance Models Functional Models Performance Models Functional Models Performance Models EXPORT PACKAGE (XMI) Integrated Health Management / Operations Layer SYSTEM ANALYSIS & OPTIMIZATION PROGNOSTIC APPLICATIONS DIAGNOSTIC APPLICATIONS MONITORING APPLICATIONS Cost/Benefit Models Flight Ops Models Ground Ops Models system is not performing as predicted or required; determine root causes, and take corrective actions. Logistics Models Mission Models Performance Metrics Physics-Based Fault Propagation Models Models Empirically-Derived OPERATIONS Fault Isolation Models Models / LOGISTICS Prognostic Analysis Object Oriented Design (OOD) Layer Design Rules Design Rules Design Rules Diagnostic Analysis Design Rules Design Rules Design Rules IMPORT PACKAGE Data Filtering State Identification Anomaly Detection Functional Models Performance Models Functional Models Performance Models Functional Models Performance Models DATA Test Model Test Model Test Model Test Model TEST PLAN IMPORT / EXPORT OPERATIONS Field Data Operation Lvl 5 Test Teams Lvl 4 Test TESTING / V&V System Test Segment Test Element Test Subsystem Test HW/SW CI Level Requirement Products DESIGN TOOLS Model-Based Design and Analysis Tools Integrated Health Management Design, Analysis, and Other Model-Based Systems Engineering Tools and Processes HW / SW CI

7 Current Design Analysis Methods Repeat Similar Thought Processes for Related Products Current Process (Simplified View) Replicated Thought Processes and Filtered Information Flow Safety Engineer System RE Reliability Engineer System RE Test Engineer System RE Tech Pubs Engineer System RE FMECA Report Hazards Analysis R&M Metrics MTTR, A o Predicts Testability Analysis Reports Test Plans Maintenance Documents IETMs Model-Based Diagnostic Design & Analysis Provides an Opportunity to Reduce the Replication of Effort in Deriving Related Products

8 Model-Based Process Reduces Duplication of Effort and Simplifies Analysis Model-Based Process System Modeler (RM&S IPT) System RE Functional Dependencies, Failure Modes, and Test Points Model R&M Metrics Logistics Simulations MTTR, A o ETOS, Predictions FMECA Reports Testability Analysis (FD%,FI%, FA%) Reports Inter-Active Electronic Tech Manuals (IETM) On-Board Fault Isolation Logic By Investing in the Development of Diagnostic Models for Systems, One Can Transition to a More Timely and Cost-Effective Automated Testability Analysis and Report Generation Process

9 Key Model Characteristics for Health Management Applications For our purposes a model must support the representation of: Physical Features and Properties of Components Static/Fixed Part (e.g., the number and type of I/O ports) Functional, Operational, Behavioral Description of Components Dynamic/Procedural/Executable Part (e.g., the function performed) Connectivity between Components Functional Dependencies and Fault Propagation Paths A Graphic Depiction of the Model That is Understandable by Users (Typically Engineers and Maintenance Technicians) Enables Efficient Model Input, Explanation, and Human Interaction

10 Example: Landing Gear Diagnostic Model Diagnostic Models Are Developed Graphically and Define WRA Functional Relationships, Failure Modes, and Tests. Fault Detection (FD%), Fault Isolation (FI%), and Other Diagnostic Performance Metrics Are Automatically Calculated

11 Input & Output Data Items Input Data Items: To Modeler: Engineering Schematics Functional Descriptions Interface Control Documents Sub-contractor Engineering Documents Directly into Model: Reliability & Maintainability Data FMECA Reports Output Data Items: Diagnostic Model Testability Analysis Reports FMECA Update Reports Diagnostic Logic / Fault Isolation Sequences S1000D Compliant IETM Data Files

12 Example of Model-Based Testability Analysis of Design Alternatives Testability Analysis of Landing Gear Design With and Without Sensor Fault Disambiguation UCAS-D Landing Gear Testability Performance Metric Before Adding Sensor Fault Test After Adding Sensor Fault Test Fault Detection Coverage (FD%) 99.9% 99.9% Fault Isolation Coverage (FI%) 65.3% 88.3% 23.0% Improvement False Removal% (The % of all WRA unit removals that could result from ambiguous fault isolation) 39.3% 18.6% 20.7% Improvement Model-Based Analysis Allows Designers to Assess the Impact of Design Options on Testability and Maintenance Efficiency

13 Health & Status Integrated Health Management (IHM), an Enabler for Integrated Operations Scenario: Detection & Multi-Level Response to Degraded Control Surface Actuation In-Flight Detection & Mgmt of Degraded Actuation System 1. Flight group embarks with all systems operational. 2. Nearing the target area, IHM detects degradation of control surface actuation and maneuverability in one of the key payload-carrying aircraft in the flight group. 3. IHM provides health & status diagnostic & prognostic information required by adaptive flight control system. 4. Control system reconfigures to maintain control and manage Remaining Useful Life (RUL) of the actuators. 5. Automated Mission Mgmt software automatically changes flight group formation and tactics to reduce vulnerability of degraded aircraft for remainder of mission. Three Tier Adaptive Control System Actuator Diagnostics/Prognostics

14 Managing Complexity in Aerospace System Development Through Model-Based Systems Engineering Aerospace Programs Require More Than 5 Times Longer to Perform Comparable Development & Sustainment Tasks than the Auto & Electronics Industries DARPA Study Results Where We Are Application of Modern Model- Based Systems Engineering, Development, Integration, and Testing, Methods Where We Need to Be Several Key Reasons for The Gap : 1. Inconsistent Aerospace Application of Systems Engineering Tools and Processes 2. Differences in Major Aerospace Systems Acquisition and Regulatory Processes 3. Lack of Model-Based Design, Analysis, Production, and/or Operations Tools

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