introduction to ivhm · r. darby, ‘commercial jet hull losses, fatalities rose sharply in 2005...

www.cranfield.ac.uk

IVHM©2018 Cranfield University All Rights Reserved

Introduction to IVHM

Prof Ian K Jennions

6th June 2019

2IVHM©2018 Cranfield University All Rights ReservedIVHM©2018 Cranfield University All Rights Reserved

Core Partners, Members & Collaborators


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


Outline

IVHM Centre

What is IVHM?

Why do we need it?


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


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


Outline

IVHM Centre

What is IVHM?

Why do we need it?


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


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

http://www.bbc.co.uk/news/uk-18751507


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


When things go wrong…


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


The Case for IVHM


• Operational:




• Economic:




‘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)


Operation – World Air Traffic


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


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


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


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


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


Embraer - AHEAD


Important to monitor usage…


The Case for IVHM


• Operational:




• Economic:




“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.


Flight Delays and Cancellations


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


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


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.


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.


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


Outline

IVHM Centre

What is IVHM?

Why do we need it?


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


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


IVHM Centre Technology


IVHM Centre Projects


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)


Test Facilities

Fuel Rig

Filter Rig

Machine Fault Simulator

IDG Rig

SIU 737-200 ECSHawk ECS

Cranfield 737-400: AID, ECS

Electronic Prognostics


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


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

introduction to ivhm · r. darby, ‘commercial jet hull losses, fatalities rose sharply in 2005...

Documents