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Health Monitoring and its Role in Safety

John McDermid, OBE FREng, University of Yorkwith thanks to

Bombardier and ESIM

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Overview

Health monitoring concepts

The role of health monitoring in safety

Examples of health monitoring Aero engines, courtesy of Rolls-Royce Railways, courtesy of Bombardier and ESIM

Benefits and opportunities

Challenges

Conclusions

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Health Monitoring Concepts (1)

Health monitoring involves assessing system components, for deterioration in their state, e.g. Ageing Damage Unexpected/undesirable properties

Often health monitoring involves Measurement Detection of “deviations” from expected state Diagnosis of root causes Recommendation of actions, e.g. maintenance

or more immediate change in operationDetails depend on the technology

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Health Monitoring Concepts (2)

Health monitoring is concerned with What has happened What is happeningMay be a focus on known faults or failure modes

Prognosis (prognostics) involves Predicting future states, including failures Suggesting courses of action to prevent failure,

or to extend time until failure occurs

In practice, distinction may be blurred Monitoring may recommend a “time for service”,

i.e. implicitly predict a safe operating period

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Health Monitoring and Safety

Health monitoring often focused on availability Ensuring action taken to avoid loss of capability

e.g. replace a motor which operates a switch e.g. correct degradation of a track

Health monitoring can positively impact safety Detect a failure/impending failure and prevent a

damaged/failing component from being used

Health monitoring can negatively impact safety e.g. the recommended “time for service” may be

too long, and a failure occurs prior to the action Greater concern with prognosis

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Health Monitoring in Aerospace

Health monitoring capabilities now widespread Main focus is on mechanical elements

Structural and rotating machinery Also considering electrical parts, e.g. generators

Rolls-Royce monitor key engine parameters Speeds, vibration, pressures, etc. Some on-board analysis, and data transmitted

for further analysis on the ground

Provide a service to airlines Includes comparison of “signatures” with known

problems from other engines

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Exploitation relies on the efficient operation of the complete system

Customer

Flight Log Sheets Ground

Station

Internet, e-mail, pagerOEM

Maintenance Centre

Act

Transfer

Acquire

24x7 Engine Health Centre

Condition monitoring,Data processing & storage,Data access & reports,Forecasting services

Analyse

Global NetworkSense

Reports via SatelliteEngine Monitoring Unit

Ground-based information, e.g. oil uplift

Continuously recorded data

Rolls-Royce Example

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Comparison –pressure signals before and after icing damage to compressor blades:

HP 1st tracked order quadrupled

IP 1st tracked order doubled

Monitoring for damage to compressor blades

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Bombardier/ESIM Example

System for monitoring track “health” Changes in gauge, alignment, and unintended

cant (angle) or twist Track moves in use, but excessive change may

necessitate maintenance (with loss of availability) Monitoring cannot make things worse, but

missed degradation may “allow” unsafe situations

System enables cost-effective approaches Use commercial trains to carry sensors Monitor more cheaply Monitor more thoroughly Significant return on investment

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The Railway Infrastructure

Geometry ofthe track

GaugeCantTwistCurvatureAlignmentLongitudinal level

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Optical Measurement System

The measurement of track parameters is doneusing laser beams and triangulation

Laserbeam

Laserbeams

Rotation

DigitalCameras

DigitalCameras

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Measuring Track Geometry

Parameters can be measured as the trainmoves down the track. For example any “twists” will be detected by changes in track rotation/angle.

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Recalibration Gantry

Static Gantry used for Recalibration of Systems on Trains

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Localisation and Synchronisation

Odometry systems

Operator

Measurementsystems

Encoding System

Odometry

ProcessingSystem

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Rolling Stock in Commercial Operation

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ESIM Track Geometry Diagnostic SystemArchitecture & Rolling Stock in Commercial Operation

GantryRecalibration service

Wi-Fi 2,4 GHz

CED

GPS Positioning

Laser 3D profiling

Assets

Odometer

Accelerometer

OpeRALocation and

SynchronisationOf Rolling Stock

Opto Electronic Railway Analisys

(OpeRA)

RailCar-BogieAcceleration

DataProcessing

Centre(CED)

RecalibrationService

System

OnBoard Wayside

Inertial Movement Unit (IMU)

RF 868 MHz

- Acquisitions- Processing- Results

Web

Remote User

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For traffic Cagliari-San Gavino:Significant events every 2 months instead of 6 months (today diagnostic plan of railway company)

17

3. Information Acquisition via SSB sensors using the

Triggers generated at the previous step

2 .Spatial Synchronisation and Trigger Generation

1. System initialisation before leaving the station

4.Acquisition of Recalibraion Information bySST

5. Download data to SST-CED on return to station

7. Calibration of data and calculation of measures

6. Data Acquisition and Validation/Reduction (10010)

8. Calculation of Importance and Classification

9. Automatic ReportGeneration

100 Acquisitions

10 Valid Measurements

1 Important Event

Measurement systems calibrated to relevant standards

Classificationof the defect

ESIM Track Geometry Diagnostic System Process of generating and analysing data

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Bombardier and ESIM are evaluating the next generation system, investigating the feasibility of integrating track geometry diagnosis with the telediagnostic system in order to have an integrated system for the vehicle and the track.

Integration of Diagnostic Systems: Bombardier/ESIM

Bombardier Telediagnostic

System

ESIM Track Geometry

Diagnostic System

Bombardier/ESIM “next generation”Diagnostic System

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Status of Work

Contract signed between ESIM and Italian Railways to permanently install system on secondary lines

Testing completed, document provided to safety agency

Certification from homologation authority expected by end of 2013

Bombardier and ESIM collaborating on the Next Generation Product

Thanks to ESIM and Bombardier for use of material

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Benefits and Opportunities

Health monitoring has significant potential benefits Better availability of track and rolling stock Fewer disruptions to operations More cost-effective maintenance

Take action prior to (secondary) damageNote: in some cases, e.g. track gauge, relatively easy to determine abnormal situations

Opportunities Generic capabilities which can be applied widely Integration of systems, making them more cost-

effective, e.g. sharing communications Avoidance of unsafe failures

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Challenges

For some diagnoses, e.g. impending failures, need historical data as a comparator or “baseline” May be hard to collect Inevitably some time before benefits obtained The more often elements are changed, the lower

the benefits (return on investment)

To take “safety credit” need to be able to show the performance of the system is trustworthy Often use complex databases, pattern matching

and heuristics, so are hard to assess against standards, e.g. EN 51028

A research problem

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Conclusions

Health monitoring used in a number of industries Aerospace perhaps the most advanced Some applications use historical data to give

accurate diagnosis of abnormal behaviour

Significant opportunities for rail systems Infrastructure, e.g. track Rolling stock, especially moving parts Can learn from others, e.g. aerospace

Most immediate benefits in availability Are potential safety benefits, but some issues to

be addressed to get “credit” for capability