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RESTRICTION ON DISCLOSURE AND USE OF DATAThis document includes data which shall not be duplicated, used or disclosed in whole or in part for any
purpose other than to evaluate this proposal and shall not be transferred nor disclosed to a third party without written consent from RSL Electronics LTD. All pages of this document are subject to this restriction
T-HUMS – Total Health & Usage Management System
AH-64 Lead The Fleet (LTF) Summary And A Glimpse At Hermes-450 MT-HUMS
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RSL T-HUMS has been evaluated by the IAF
2002-2004
LTF (lead the fleet) 4 AH-64 aircraft
Daily missions (training & operational) & seeded fault tests
Program track record validated the benefit of safety availability and savings
Similar success was accomplished in UAV
As a result, the following 3 T-HUMS programs exist at the IAF
AH-64A
CH-53
Hermes-450 UAV
Decision to proceed into UH60 T-HUMS & AH64D T-HUMS
OverviewOverview
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Validate T-HUMS ability to address AH-64A “hot issues”
MGB/AGB clutches
VIB-GRBX
APU clutch (new)
SDC (new)
Reduce maintenance flights with focus on RT&B
Demonstrate the potential for CBM / individual maintenances – by matching alerts & facts
Enable decisions - HUMS for the IAF major fleets
Primary LTF ObjectivesPrimary LTF Objectives
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Model-based diagnostics & prognostics
Focus on internal components
Low dependency on former experience / tests
Synergy among all T-HUMS programs
Automatic in-flight diagnostics & decisions in real-time
In-flight advisories
Fast algorithms – true continuous mode
“Safety guards” – Novelty, RMS
Efficient RT&B algorithm
Compact, yet powerful hardware
Small footprint (downloads & analysis)
TT--HUMS Key FeaturesHUMS Key Features
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Interface with existing sensors and 1553 bus
AHAH--64 T64 T--HUMS HUMS –– Top LevelTop Level
Cockpit X 2
NGB R X 1NGB L X 1
Eng R X 2Eng L X 2
Tail Shaft X 2
TGB X 2
IGB X 1
MGB X 8
APU X 1
Ground Station
Integrated flight line system (IFLS)
3 co-processors
Up to 6 GB memory
Classified1
The TThe T--HUMS Information FlowHUMS Information Flow
Flight-line A
Base 1
Detachment B
Fleet Management
Detachment A
Diagnostic Center
Web
Logistic systems
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Pilot DisplaysPilot DisplaysAdvisoriesRT&B Initiated recordingEngine power checks
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IFLS IFLS –– Integrated FlightIntegrated Flight--Line SystemLine System
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Ground Station SpecificationsGround Station Specifications
Functions
Automatic data and diagnostics screening
View alerts
Data analysis
Usage tracking
Manage maintenance
Generate reports
Database management
Configuration management
Web GUI & application
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AH64 TAH64 T--HUMS Track Record SummaryHUMS Track Record SummaryOver 2000 flight hours
~ 550 G Byte data
~ 2000 pointers monitored per each relevant FR
RT&B – average of 1.6 iterations
Initial (current) performance - Detection 94-97%, FA rate 0%
Type of event
Relevat events
Detection counter
Notes
VIBGRBX 15 1 out of the 15 cases, one is a real failure. The rest are false alarms of the VIB-GRBX sys
NGB 7 7SDC 3 2.5 consider SDC sensor upgrade to 30 kHz
MGB 3 3 Detection via failure propagation in the MGB. Improve algorithm for planetary gears
Engines 1 1 FOD
Generator 1 1Total 30 15.5
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Trending Of Vibration FeaturesTrending Of Vibration Features
BL1 2 3 4 1 2 3 4 1 2 3 4
BL BL
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IGB DeteriorationIGB Deterioration
IGB modulation – inlet shaft (5) sidebands
Unbalance of shaft 5 (IGB inlet shaft)
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NGB NGB –– Ball Bearing Ball Bearing –– 11/200311/2003
Confidence level
Inner race Inner race sidebands
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Trends Trends –– Cracked BracketCracked Bracket
Structural vibration change (left chart) picked by the novelty detection algorithm (right chart)
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Crack growth on MGB housingCrack growth on MGB housing
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FOD DetectionFOD Detection
0 50 100 150 200 250 300 350 400-0.05
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
02-Feb-200402-Feb-2004
fault probability Nnomfault probability NomdecisionSnapShotNomTrendNomSnapShotNotNomSnapShotNotNomTrendNotNom
905 - Engine Left Accessory - NG shaft
Misalignment code: 127 => Trend dates: from 24-Feb-2003 to 02-Feb-2004
Decision Process
Nominal Trends
Energy growth of NG pointers (unbalance and misalignment) starting from the 1st flight 2-2-2004
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MGB/AGB ClutchMGB/AGB Clutch -- Seeded Fault TestSeeded Fault Test
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FRR and Fatigue
Automatic Regime recognition Enables fatigue tracking
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RT&B
Scale…
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OverOver--Torque MishapTorque Mishap
Fuel System
EnginesFlight Controls
Uncontrolledtouchdown
Over-torque
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Safety
Flight hours
Maintenance
Availability
Operational
TT--HUMS Benefit Analysis & ForecastHUMS Benefit Analysis & Forecast
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AH64 TAH64 T--HUMS Benefits HUMS Benefits –– SafetySafety
Prevention of dual MGB / AGB clutch failure (failure means no hydraulics & no AC power)Prevention of APU clutch failure (failure can cause fire)
Prevention of generator in-flight failurePrevention of SDC in-flight failure (failure can cause fire)
Prevention of NGB in-flight failurePrevention of false VIBGRBX warnings (existing a/c system)Prevention & detection of FOD BDA
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Maintenance flights with a fully qualified crew - handle aircraft emergencies (*)(**)
Clear information on in-flight failures – less room for error at the cockpit
Lower vibration – less physiological stress
Lower workload – power checks, recording…
Mishap analysis = risk reduction
Less maintenance (& ground runs) = less room to make errors = safety
(*) A Team work enables the correct answer in case of in-flight problem(**) Without T-HUMS – a technician is needed instead of front pilot
AH64 TAH64 T--HUMS Benefits HUMS Benefits –– SafetySafety
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Flight Hours Savings Flight Hours Savings Reduction of RT&B maintenance flights (*)
Pilot initiated ~ 90% reductionAfter maintenance ~ 70-50% reductionNight time executable and without a technician
Reduction of engine maintenance flightsHIT & Power checks ~ 80-90% reduction (*)Post FOD replacements ~ 70-90%
Reduction of maintenance flights after scheduled maintenance Planned MGB removals ~ potential increase from 900 to 1800hPlaned pitch housing replacements ~ potential increase from 620 to 1200-1800hFuture expansion of inspection & maintenance intervals ~ potential increase ~ 30-60%
(*) Most resulting maintenance flights will be executed after maintenance activity (such as after I-level inspection or engine removals) and not to initiate maintenance
Lower by~ 90-80%
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OO--Level WorkLevel Work--Load Reduction Load Reduction Reduction tail VIBGRBX ground runs ~ 95%Reduction of tail rotor balancing ground run
Pilot initiated ~ 90% reductionAfter maintenance ~ 50% reduction
Reduction of APU & Engines ground runsFault confirmationTroubleshooting ~ 50-70%
Prevention of :Unneeded removals of dynamic systems ~ 90% reductionUnneeded ground runs due to tail vibration (VIBGRBX)
FOD related engine removals ~ reduction of 70-90%Troubleshooting time (drive train, rotors, engines, fuel system) ~ direct effort cut by ~ 70-90%
Lower by~ 90-70%
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OO--Level BenefitsLevel Benefits
Minimal dependency on experts including for RT&B flights
No need to install instrumentation (GSE) for testing
Less scheduled maintenance – inspections & removals
Less non-required maintenance – parts & labor
Less AOG
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DD--Level Maintenance Savings Level Maintenance Savings Prevention of FOD engine repairs ~ reduction of 70-90%Gearboxes overhaul cost of replaced parts - reduction of
All “chips initiated” ~ 50% (due to on-time removals and smaller damage)Replacements IAW diagnostic report
Extending the overhaul intervalsPlanned MGB removals ~ potential increase from 700 to 1800hPlaned pitch housing replacements ~ potential increase from 620 to 1200-1800hFuture expansion of inspection & maintenance intervals ~ potential increase ~ 30-60%
ROM Saving~ 50%
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Potential to:
Reduce inspection tasks - shorter
Increase intervals ~ (20-100% - case sensitive)
Lower overhaul cost
Lower cost – labor & parts
AH64 TAH64 T--HUMS Benefits HUMS Benefits –– Inspections & Scheduled Inspections & Scheduled Maintenance Maintenance –– All EchelonsAll Echelons
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Deployments
Smart selection of deployed helicopters
Less GSE needed – smaller logistic foot-print
Special missions
Correct selection of best helicopters for the mission
Deployments & Special MissionsDeployments & Special Missions
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Crisis
A new failure mode found
The fleet is grounded for inspection & tests
Significant management attention
T-HUMS enables
Fast screening
Risk planning and reduction
Quick recovery to normal operation
Crises HandlingCrises Handling
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Additional helicopters daily at the flight-line
Fleet availability – 10-15% higher
Faster recovery from crises
Operational ReadinessOperational Readiness
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Squadron Commander POVSquadron Commander POVLess maintenance flightsLess mission aborts (ground & air)Higher mission reliabilityLess workload on aircrewMore daily available aircraftLess interruption to training and operationsLess deployment overheadsNight time executable maintenance flightsDebriefing capability:
Tactical debriefingFlight quality & aircraft handling (supporting MFOQA)Mishaps analysis
Simpler squadron managementMore effective squadron operationBetter training & readiness
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Fleet Manager POVFleet Manager POVMore successful missions with less aircraftHigher readiness level and availability of the fleetMore effective fleetLower flight hour costLess management overheads
Lower budgetBetter force build up
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SummarySummaryT-HUMS – A different type of HUMS
The AH64 T-HUMS LTF Program had met its objectives
T-HUMS works
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Glimpse at Glimpse at Hermes-450 MT-HUMS
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Airborne Segment
MTMT--HUMS Data FlowHUMS Data Flow
Ground Segment
Ground control Stations
Integrated Flight-Line System
(*) Implemented without the OEM
Ground Stations
Insurance policyfor low-intensity
high-demand mission
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Altitude (up to 15KAltitude (up to 15K’’) & Vibrations) & Vibrations
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Engine ParametersEngine Parameters--Based DiagnosticsBased Diagnostics
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Ignition Circuit #1 Failure Ignition Circuit #1 Failure
Ignition current #1 (RMS) drops to zero during climb
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SummarySummaryProven MT-HUMS/T-HUMS technology COTS MT-HUMSValidated MT-HUMS performance & benefits MT-HUMS
Insurance policy for UAVs – platform, payload, mission & operationIncrease MTBL and MTBUSV
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Contact RSLContact RSL
Artificial Intelligence
Vibration Analysis
Electronics Hardware
Knowledge of Aerospace engines
Software applications & GUI