Les besoins en maintenance chez EUROCOPTER : les principaux axes d amélioration de la maintenance des hélicoptères

Transcription

1 Les besoins en maintenance chez EUROCOPTER : les principaux axes d amélioration de la maintenance des hélicoptères

2 Helicopter Maintenance Research in maintenance Availability and cost modelling Reliable Design Maintenance credit New Health monitoring solution Innovative Diagnostic RFID Logistic mean

3 Maintenance objectives Cost Safety Decrease the maintenance costs Make the maintenance work easier Increase Safety with maintenance low cost actions Availability Increase the aircraft availability Business Improve the EC business in terms of Maintenance & Service Propose a meaningful service/product combination

4 helicopter maintenance specificities Airplane Helicopter Wild body véhicule compact Equipments all over the AC Centralized equipments Same product for each AC Personnalised and adaptable HC

5 helicopter maintenance specificities Airplane Helicopter Long range Take off and landing = stress One mission type A lot of different mission High altitude Less than 5000m

6 helicopter maintenance specificities Airplane Helicopter Low vibration stress Hight mechanical stress Specific customer Diversity of customer Availability as priority Failure localisation to avoid no failure fond The airplane and the helicopter are two vehicules using the same maintenance mode but in different objectives and different stress.

7 The group Helicopter Maintenance Research in maintenance Availability and cost modelling Reliable Design Maintenance credit New Health monitoring solution Innovative Diagnostic RFID Logistic mean

8 Maintenance Research major axis II - Reliable Design I - Availability and cost modelling III - Maintenance credit IV - New Health monitoring solution Sensors Sensors Intelligent sensors, able to monitor and send back their state Sensor New developments Integration of testability all along design phases Suppression of testability demonstration Computer LRU Equipments/ Tools System Diagnostic table Evolution of diagnostic table, Adaptability to helicopter's options Display of the results in order to ease comprehension of maintenance operations Interface Failures Test words emission on interfaces Old/new avionics Interfaces How to test COTS and old avionics interfaces Failures localisation Tools, on ground Documentation Trouble shooting RTG Troubleshooting Trouble shooting V - Innovative Diagnostic VI - RFID Logistic mean

9 The group Helicopter Maintenance Research in maintenance Availability and cost modelling Reliable Design Maintenance credit New Health monitoring solution Innovative Diagnostic RFID Logistic mean

10 Scenario modeling NTI 1 Inspection / Servicing Pilot Flight engineer Base (NTI 2) Pilots Failure A/C to Overhaul Flight engineers Flight Planning Certified Station NTI 1/2/3 Periodic inspection Non scheduled maintenance Trouble shooting Equipment to Overhaul Engines Manufacturer Workshop Planning

11 Availability modeling 7008 h=80% Flying time 500 h = 6% Effective time of availability 6508 h = 94% Servicing Waiting time Effective waiting time 473 h = 50% Total time= Time required= 8760 h 1577 h = 18% /FH Effective time of unavailability 946 h = 60% Predictive maintenance period Systematic maintenance period 473 h = 50% Additional maintenance period 631 h = 40% Unavailability time for corrective maintenance 536 h = 85% Active time of corrective maintenance 95 h = 15% Spares supplying period Failure research & diagnosis period Reparing period 180 h = 2% Unavailability due to external reason Maintenance implementation period

12 Distribution of the life cycle costs Ecodesign Performances Hardly reducible Withdrawal Acquisition 25% Reliability Indirect Maintenance Utilization 10% Internal Maintenance Direct Maintenance Cost 35% 1500 /h Insurance 15% Production costs Maintainability

13 The group Helicopter Maintenance Research in maintenance Availability and cost modelling Reliable Design Maintenance credit New Health monitoring solution Innovative Diagnostic RFID Logistic mean

14 Reliability optimization Product Reliability Process Environment

15 The approach «Control of the avionic environment» Prediction of the future H/C DMC Data base of DMC adjusted Constraints to reduce Prevision of the constraints profitable to control Profitability of the systems Design of the reducing constraints systems Technico-économical evaluation of the systems Selection of the most profitable systems Quantified Systems

16 Which constraints to control? Where controling them? DMC observed K Location in The H/C acc predicted DMC predicted acc optim DMC optim Saved DMC Calculator AP 6$/h 3 Nose 1,5 4,5 /h 1 3 /h 1,5 /h Visual MFD 5$/h 2 Instrument panel 2 3 /h 1,5 4 /h 1 /h Temperature Spectrum in observed environment Temperature spectrum in predicted environment Temperature Spectrum in controled environment

17 Design to Reliability Profit of DMC Profit of DMC (1) Reliability service Reliability service (6) Thermal atmosphere Thermal atmosphere (2) Thermal service Thermal service (5) Specification Technical performances Cooling systems (3) (4) service Selection of the product in the market Technical performances Definition

18 The group Helicopter Maintenance Research in maintenance Availability and cost modelling Reliable Design Maintenance credit New Health monitoring solution Innovative Diagnostic RFID Logistic mean

19 Health monitoring for Maintenance Health Usage Moteurs Data acquisition on board Utilitaires Trains Warning Avionique! Structure Ground level maintenance maintenance Architecture Detection / Localisation Diagnostic Troobleshooting Maintenance tasks maintenance Opérateur

20 Maintenance credits N Δ TBO TTF Increase the Time Between Overhaul H Anticipation de panne Maintenance corrective

21 Maintenance credits Decision support Corrective maintenance Interface Indicators Health & Usage Monitoring System (HUMS) Interpretation HEALTH USAGE Vibration analysis Acquisition Flight data HOMP

22 Maintenance credits Decision support Health-based maintenance planning Maintenance credits Interface Vehicle Monitoring for Maintenance & Health Management System First failure symptoms Before failure Interpretation HEALTH CORRELATION USAGE Vibration analysis Acquisition Oil Analysis ADHER Stress-Strain Analysis SHM CESAR Flight data HOMP

23 The group Helicopter Maintenance Research in maintenance Availability and cost modelling Reliable Design Maintenance credit New Health monitoring solution Innovative Diagnostic RFID Logistic mean

24 New health monitoring solution for Pronostic For avionics For Structural parts

25 Pronostic for avionic Contraintes environnementales: - Cycles thermiques - Sollicitation vibratoires - Corrosion chimique - Hygrométrie Dégradation élémentaire induite Micro-HUMS integrated sentinel Continuous monitoring Evaluation of external solicitations

26 SRU Pronostic Implementation Prototype environment Identification Calculation of degradation Sum of the elementary damages Micro-HUMS ni Damage= i CTF i weak or defective population BIHM DEGRADATION CALCULATION ALGORITHMS

27 Eurocopter Structural Monitoring Propose a new concept for the maintenance and the operational use of the airframe part of the helicopter Integration of Structure Health Monitoring for : Flight tests Major incident Repairing follow-up for difficult access points To develop a specific tool to exploit diagnosis structure results Maintenance tools for composite, metalic failure diagnostic

28 Structural Health Monitoring - Ultrasonic Sensors. Materials of the Tail Unit Demonstrator A-Scan of the upper Skin - Glass cloth / epoxy : 0.05 mm - Bronze grid 50g/m² - 1 ply of carbon /epoxy fibre bi directional : 0.22 mm - 3 plies of Carbon /epoxy fibre uni directional : 3 x 0.17 mm - 1 ply of carbon /epoxy fibre bi directional : 0.22 mm - Film of glue epoxy - Sandwich of Nomex honeycomb: 15 mm - 2 plies of hybrid carbon /glass fibre resin epoxy: 0.25 mm - Film TEDLAR Ultrasonic imaging of the upper skin Ultrasonic imaging of skin and core Visualisation of Lamb wave fields

29 The group Helicopter Maintenance Research in maintenance Availability and cost modelling Reliable Design Maintenance credit New Health monitoring solution Innovative Diagnostic RFID Logistic mean

30 On board failure management Problematic links to the aircraft diagnostic False Failures : False warnings Failure Localisation Ambiguity (intrinsic) Failure Propagation All these problematic lead to : false removal (between 30 and 40% of maintenance operations) Longer maintenance time Lost of confidence in the diagnostic tool Customer is not satisfied

31 Diagnostic innovation Sensor data correlation algorithm Genera te a failure algorit hm robust to option al and export able to other helicop ters Telemaintenance AFCS VMS DISPLAY AMC FDS SENSOR 1 SENSOR 2 SENSOR n Logical and Temporal Correlation of failure messages Ethernet Correlation with complementary data GSC Inte grat es expe rien ce feed - back maintenance computer

32 The group Helicopter Maintenance Research in maintenance Availability and cost modelling Reliable Design Maintenance credit New Health monitoring solution Innovative Diagnostic Logistic mean

33 RFiD for logistic means LOGISTIC ENVIRONMENT GROUND ENVIRONMENT AERONEF ENVIRONMENT Flotte hélicoptères FLEET MANAGEMENT Filiales réseau mondial DOCUMENTATION Analyse usage / santé Planning révision Gestion de configuration Base de données globale CONFIGURATION / HEALTH, USAGE DATA / WARNING MESSAGES CONF DATA Maintenance data transfert (PN / SN ) BSITAG LINK WITH INDUSTRIE Customer stock Repair center DATA CONCENTRATOR

34 RFiD for health monitoring Concept : Assume the part following with RFId integrated snesors Wireless On ground and in flight Objective : Usage monitoring In storage : monitoring of hter storage condition associated to the mechanical containers In usage : Monitor the real usage condition in the HC impact on flight planning HUMS HUMS HUMS HUMS Monitoring in storage Monitoring in flight

35 Thank you for your attention