introduction to ivhm · r. darby, ‘commercial jet hull losses, fatalities rose sharply in 2005...
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Introduction to IVHM
Prof Ian K Jennions
6th June 2019
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Core Partners, Members & Collaborators
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Ian - Career
1970 1980 1990 2000 2010
Mechanical Engineering Degree:- Mathematics
- Fluids
- Thermodynamics
- Structures
- Materials
- Design
Degree
PhD in Computational Fluid Dynamics
- very new
- contentious
- many problems
PhD in CFD
Rolls-Royce General Electric Alstom Rolls-Royce
UK USA Switzerland UK
Professor,
IVHM Centre
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Outline
IVHM Centre
What is IVHM?
Why do we need it?
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Integrated Vehicle Health Management
...the transformation of system data into information to support operational decisions that results in:
• Minimised maintenance action/time
• Enhanced operational awareness
• Improved readiness and availability
• Reduced inspections and troubleshooting
• Reduced redundancies & design margins
• Reduced schedule interruptions
• More efficient logistics operations
• Reduced environmental impact
- hence creating real business benefit
…multi-sector application:
• Aerospace
• Marine
• Automotive
• Rail
• Energy
• Health• Agriculture
• Manufacturing
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Health Management Architecture
• Production, certification & testing
• Total ownership costs• System & life cycle • Requirements• FMECAs• Design models• Failure modes/models• System test data
Design
Engineering
Manufacturing
• Maintenance Scheduling• Spares Supply• Asset Tracking• Maintenance Execution
Vehicle Maturation/ New Product
• Operational Demand• Fleet Availability• MR & O leading
• Operational Schedule• Operational Effectiveness
Health Status
ActAcquire
Transfer
Sense
Health Status• Current• Predicted
Analyse
Data Repository
& Ground Processing
Maintenance &
Logistics
Operational Control
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Outline
IVHM Centre
What is IVHM?
Why do we need it?
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The Case for IVHM
• Safety – NASA case
• Operational:
– Major growth in passengers
– Pressure for increased availability
– Greater capacity requires greater reliability
• Economic:
– Predictability and risk management
– Service business efficiency
– Maintenance cost reduction
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Consequences of not knowing when something is going to fail
TransAsia Flight 235 (2015) – engine flameout followed by human error
Potters Bar crash
(2002) – points
failure
M4 closure (2012) –
road infrastructure
failure
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Safety - System / Component Failure / Malfunction(SCFM) events
Ref: ‘Commercial Aircraft Integrated Vehicle Health Management Study’, M.S. Reveley, J.L. Briggs, J.K. Evans,
S.M. Jones, T. Kurtoglu, K.M. Leone, C.E. Sandifer, M.A. Thomas, NASA TM 2010-215808, February 2010
Covers 5 years 1998-2003 Major airlines Commuter Time negotiated
Cargo carriers >10 seats with customer
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When things go wrong…
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2005 Accidents
R. Darby, ‘Commercial Jet Hull Losses, Fatalities Rose Sharply in 2005 –
The Year’s Numbers…’ Aviation Safety World, August 2006,
www.flightsafety.org
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The Case for IVHM
• Safety – NASA case
• Operational:
– Major growth in passengers
– Pressure for increased availability
– Greater capacity requires greater reliability
• Economic:
– Predictability and risk management
– Service business efficiency
– Maintenance cost reduction
‘Within Europe the number of
commercial flights* is up to 25 million
in 2050 compared to 9.4 million in
2011’Flightpath 2050 and Eurocontrol (2011)
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Operation – World Air Traffic
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Aerospace Growth Figures
... unobtainable without Integrated Vehicle Health Management
• Boeing Market Forecast for Commercial Aviation:
– Expectation that the 2012 trend will continue over the next 20 years, with
world passenger traffic growing 5.0% annually.
– Long-term demand for 35,280 new airplanes, valued at $4.8 trillion!
– Approximately 70% of new deliveries will be single-aisle airplanes,
reflecting growth in emerging markets such as China, and the continued
expansion of low-cost carriers throughout the world.
• ACARE have published Flightpath 2050:
– 90% of travellers, door to door, anywhere in Europe < 4 hours
– <1 accident per 10M flights
– Air Traffic Management will need to handle 25M flights/year
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UTAS on the B787
• First revenue service with ANA November 1st 2011
• Monitoring over 2000 parameters on H-S equipment: LP fans, power
electronics cooling, integrated coolers, N2, electrical power distribution
and control
• Aircraft (ACMF) provides 47 different reports
• Reports downloaded via ACARS
• Ground based system looks for data every 4 minutes
• Value: reduced warranty costs
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Growth in India
• 86 cities have airports, potentially 450 more near economic growth
areas
• ATM critical
• Aviation growth 16%
• Point to point focus (56% of routes 200-800 kms)
• Main airports already operate 24/7
• NCAD 90 seater, 2500 nm range
... IVHM seen as crucial to achieving goals
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Railway Network in India
• 71,000 miles of track
• World’s 4th largest railway
• 30M passengers / day
• 1.36M employees
• 240,000 wagons
• 60,000 coaches
• 9,000 locomotives
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Operational Service Offerings
Bombardier C series
G650 (GE enabled)
Boeing: Gold Care
Rolls-Royce: Total Care
Boeing: AHM
Honeywell: Zing
Embraer - AHEAD
Airbus - AIRMAN
P&W: CAMP
B737 - CMC
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Embraer - AHEAD
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Important to monitor usage…
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The Case for IVHM
• Safety – NASA case
• Operational:
– Major growth in passengers
– Pressure for increased availability
– Greater capacity requires greater reliability
• Economic:
– Predictability and risk management
– Service business efficiency
– Maintenance cost reduction
“The financial benefits from an
airline’s point of view could be
considered as providing
predictable cost and risk
management” Robert Merrill, Director Service Programs, Pratt &
Whitney.
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Flight Delays and Cancellations
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Causes of Flight Ds&Cs
Air Carrier: The cause of the
cancellation or delay was due to
circumstances within the airline's
control (e.g. maintenance or
crew problems, aircraft cleaning,
baggage loading, fueling, etc.).
iFly.com –
passenger
perspective
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Service Business Efficiency
½ hour
2 hours2 hours2 hours
2 hours 2 hours 2 hours 2 hours
Flight
Contingency
3 Flights per day
4 Flights per day
• Focus on Delays and Cancellations
• Identifying problematic LRU critical
• Cost Delta $385M/year
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IVHM Maintenance Credits
• In order to keep an asset operating beyond its scheduled maintenance
period, on-condition monitoring and management, certified by the
regulator, is needed. This process improvement change would earn a
Maintenance Credit.
• While on-condition monitoring and management are seen as the future
(CBM, ALS, etc) very few Maintenance Credits have been obtained;
most data is treated as advisory.
• If IVHM data can be used to alleviate the need for costly maintenance
that results in unnecessary down time then the IVHM data needs to be
creditworthy.
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Maintenance Credit Examples
1. EGT margin calculation is done to determine how much the efficiency
of the turbine has deteriorated. The engine is pulled based on its
condition and not based on a scheduled interval.
2. Engine vibration levels. Depending on the engine vibration levels, a
time limited dispatch can be made before bringing it in for servicing.
3. ETOPS capability is determined by EHM systems. Most operators use
IVHM to determine how much MCT (Max Continuous Thrust) margin
remains before dispatching an aircraft.
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Outline WelcomeFIA2016 – Workshop with Operators/MROs
SAE – International Standards Workshop, 12 July 2016, FIA2016
Achieving Maintenance Credits
Tuesday 12 July 2016, 08:00 to 12:00
Aim: Obtain Operator/MRO engagement and input into on-going process to develop standards
in the following areas:
a) Collaborating with Regulators
b) Recommended Practices for Maintenance Credits Processes
c) Recommended Practice for Data Interoperability
Agenda:
Welcome
Keynote Speaker (TBC)
Facilitated breakfast sessions to obtain feedback on evolving standards documents
Panel Discussion
Working meetings
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Outline
IVHM Centre
What is IVHM?
Why do we need it?
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First 5 Years > Second 5 Years
• Mature research/technology base – becoming world recognised
• Over 35 projects, over 75 technical papers & 5 books (edited)
• Internationally recognised short courses
• Influencing international policy and standards
• 10:1 leverage achieved
• Revenue doubled up to £2m/yr
• New sectors: Rail, Health, Energy, Agriculture…
• Over 20 staff + access to rest of University
• Higher TRL – Firewalled Applied projects
• Realising business benefit
• Sub-system/Platform/Fleet level integration
• Focus on reliable diagnostics and prognostics
• Targeting multiple sector applications
• Increasing world recognition
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IVHM Centre Development
20112007 2008 2009 2010 2012 20142013
Centre Director
1st Academic on Core
Team Achieving Gearing – 10:1
First TRL6 Achieved
Health Hub
FALCON
ECS
20162015
-AIRMES
- 737 Demo
2017
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IVHM Centre Technology
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IVHM Centre Projects
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IVHM Centre Applied Research
• FALCON SIM – Smart Grids
• Alstom Transport - Health Hub – Train Maintenance
• RepAir (FP7) – Prognostics and Additive Manufacturing
• MBD – Next generation landing gear
• Demon UAV – flying test bed (TRL4)
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Test Facilities
Fuel Rig
Filter Rig
Machine Fault Simulator
IDG Rig
SIU 737-200 ECSHawk ECS
Cranfield 737-400: AID, ECS
Electronic Prognostics
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737-400 Demonstrator
• Signed up to MyBoeingFleet
• Engine being sought for ground operations
• AID (Airplane Interface Device) - low cost retrofitable data bus access to support health management and interface to crew wireless devices
• First demo projects being defined: ECS, APU, Wireless Systems
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Education and Publications
Published at
AeroTech, Seattle,
September 2015
IVHM Modules – offered
throughout the year
IVHM Short
Course – has
run for 7 years
Launched at
AeroTech,
Toulouse, October
2011
Civil Aircraft of the
Future,
RAeS/Boeing/Cranfiel
d Conference Nov
2011, Nov 2013, Nov
2014
Maintenance Credit
Workshop, April 2015
Published
November 2012
Published at
AeroTech, Montreal,
September 2013
Published October
2013
Published October
2014
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