SIKORSKY’S HEALTH MANAGEMENT JOURNEY: PAST, PRESENT …

This page contains no technical data controlled by the ITAR or EAR.

© Unpublished Work, Sikorsky Aircraft Corporation (SAC) 2015. All Rights Reserved.

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SIKORSKY’S HEALTH MANAGEMENT

JOURNEY: PAST, PRESENT AND FUTURE

James P. Cycon

Manager, Health Management Systems

Sikorsky Aircraft Corporation

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This document contains no technical data controlled by EAR or ITAR.

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Airworthiness, CBM and HUMS Specialists’ Meeting

Huntsville, Alabama / February 9-11, 2015




SAC HEALTH MANAGEMENT EVOLUTION

2

S-92A®

CH-53E

S-6™

S-76C++™

CH-53 HLR

UH-60A,L,M

MH-60S/R

S-76D™

CH-148

SAFETY

MAINTENANCE & TROUBLE SHOOTING

CONDITION BASED MAINTENANCE




SAC HEALTH MANAGEMENT VISION

3

Eliminate Unscheduled Maintenance

Optimize Scheduled Maintenance

Focus Troubleshooting & Reduce False Removals

Maximize Detection Time Before Failure

Enhance Safety




S-92® HEALTH MANAGEMENT SYSTEM

4

S-92® Operators

HUMS

Collected

Data

Customer Sikorsky

Web Portal KDT

CI Box Plot

SPLAT Matlab

Data Transfer

Multiple time a day

Proactive Support

HUMS/Maintenance

Data & Field Events

New HUMS Tools

VALUE TO THE OPERATOR

New HUMS tools, maintenance credits, etc. Retirement

Time

Adjustment

S-92 ® Hub

Helicopter Flight Data Mgt.

MFD Ground Based

Application

“Check HUMS”




S-92® TEN YEARS OF MATURATION

5

Downtime Avoidance

High-sensitivity vibe analysis enabled

early detection of degrading health and

proactive response.

New Detection Capability

Research isolated vibe-signature of

previously undetectable Pivot Bearing

issue and enabled software enhancement

Extended Time-on-Wing

Leveraged S-92® Main Rotor Hub life

adjustment to gain additional retirement

time adjustment credits from the FAA

Level-of-Repair Optimization

Identified opportunity to significantly

reduce removals of APU Generator - a

top AOG driver

S-92® FMOC

Now 250+ aircraft

650 GAGs*

Outer

Plate Edge

Base of

Center

Post

120% Tp

10GB+ data daily




EXTENDING TIME-ON-WING

6

LLP Retirement Extension (Serial #)

FAA approved S-92® main rotor (MR) hub life

Average benefit of 50% one-time CRT

extension

Data Driven

Inspection

Ro

tor

Sp

ee

d (

rpm

)

50 sec @ 58% RPM

4 min @

39% RPM

2 min @ 50% RPM

Avoid Range

Time

Focused

Troubleshooting

0

20

40

60

80

100

120

140

160

180

0-105 0-110

Rotor RPM Ground Air Ground Cycle

Oc

cu

ra

nc

es

Design

A/C 11

A/C 12

A/C 13

A/C 14

A/C 15

Fleet Avg

Rotor Cycles

0

20

40

60

80

100

120

140

160

180

0-105 0-110

Rotor RPM Ground Air Ground Cycle

Oc

cu

ra

nc

es

Design

A/C 11

A/C 12

A/C 13

A/C 14

A/C 15

Fleet Avg

Rotor Cycles

Component

Retirement

Adjustment

S-92 MR

Hub

Fleet Mean ~ 0.6

STD ~ 0.5

~260 Hours

Left Accessory GBX Bearings

Operator

Alerted

Health AlertsAccessory Gearbox

Accelerometer

Location

Abrasion

Strips replacedInspected No

Fault Found –

Rebalanced

Dis-bonded

Pivot Bearing

Tail

Roto

r V

ibra

tion

(ip

s)

Calendar Time

Maintenance Triggers

1/1/20091/1/20081/1/20071/1/2006

3500

3000

2500

2000

1500

1000

500

0

Removal Date

Flig

ht H

ours

at

Rem

oval

Bearing Faulty or worn

Indeterminate

Interference

Scheduled

Vibrations

Code

Scatterplot of Hours on Oil Cooler Blower at Removal Date

Lost Opportunities

Assignable Cause

TBO

Extension

1/1/20091/1/20081/1/20071/1/2006

3500

3000

2500

2000

1500

1000

500

0

Removal Date

Flig

ht H

ours

at

Rem

oval

Bearing Faulty or worn

Indeterminate

Interference

Scheduled

Vibrations

Code

Scatterplot of Hours on Oil Cooler Blower at Removal Date

Lost Opportunities

Assignable Cause

TBO

Extension

TBO Extensions

Clear Outlier

Fleet

Analysis

Level 1 Limit 0.37 G




Anomaly Detection

New Condition

Indicators

Fleet Spectrum Update (Part #)

Virtual Monitoring of Loads (VML) used to calculate TR torque from 500kFH

Load statistics used to revise usage spectrum 3.25X retirement time

TR

Po

we

r (H

P)

Cumulative TR Power Spectrum




“BIG DATA” ANALYTICS APPLICATIONS

7

Hadoop® Cluster • The new paradigm – cloud computing • HADOOP by Cloudera

• HADOOP = An open source implementation of MapReduce, a powerful for deep analysis of very large data sets.

Analysis across the entire

fleet (16+ Tb) in a few minutes.

Fleet

Distribution

Tail Distribution

Custom queries

across fleet-wide

parametric data

Fleet-wide

statistical

analysis




EXPANDING ANALYTICS

8

Optimizing support through awareness and insight

Fleet Demographics Health Monitoring and Drill-Down Cost/Maintenance

Trending and Investigation

Supply Chain Optimization Maintenance Optimization Text mining and Statistical

Analysis




PHM SYSTEM INTEGRATION LAB (SIL)

9

Architectural Elements Developed in Parallel to Subsystem Technology Maturation




SIL PLAYBACK SYSTEM

10

Primary Functionality

Challenges

• Seamlessly merge integrated

flight data, seeded fault data,

simulated data

• Playback data to fully

simulate avionics system

• Specifying and developing

intuitive user interface

• Converting often massive,

heterogeneous data files to

common format

• Defining and implementing

playback interfaces

Playback System

Man Machine Interface

COST-A

Emulation

Unit

Signal

Interface

Unit

Vibration

Emulation

Unit

System Under Test

Simulation Offline Element

Aircraft

Simulation

Engine

(GenHel)

PHM SIL

Live

Test

Stands

Sikorsky

Local Area

Network

Other Aircraft SIL(s)

Ground Test Stand(s)

Recorded Data

PHM SIL

Enabling capability for PHM Development and Testing




• Immediate access to data

• Shortened post flight

process

• Automated post flight

process

• Standard communication

protocols

REAL-TIME DATA DOWNLOAD

11

Satellite Message

• Small Offload (~10Kbytes)

• Push Only

• 2.4Kbits/s

Cellular Message

• Partial On-Demand Offload (~1MByte)

• Push/Pull

• Ground can request additional data

• 300KBits/s (3G)

At Wing

Wi-Fi Message

• Full Offload of MUD File

• Up to 256MBytes

• 54MBits/s

Tablet

Internet

Flight Operations Center

• timely access to information




Fleet View

Tail Summary

Drilldown

Wireless

Transmission

MOBILE MX TOOLKIT WORKFLOW

12




SAC GROUND BASED APPLICATION

13

Sikorsky SGBA Key Functions

Operation Usage

Mechanical Diagnostics

RTB

Flight Manual Exceedances

Alert Trending

Parametric

HUMS Toolbar




INCREASING THE VALUE OF HUMS

14

Expand Safety Attributes

Incorporate into

Aircraft Delivery

Process

Change the Design Paradigm

Transition to CBM+




Questions?

15

Questions?

Documents

SIKORSKY’S HEALTH MANAGEMENT JOURNEY: PAST, PRESENT …