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Engineering, Operations & Technology
Copyright © 2015 Boeing. All rights reserved.
Boeing Research & Technology
Structural Health Monitoring and Its Role in Affordability
10th International Workshop on Structural Health Monitoring
Stanford University
2 September 2015
Naveed Hussain
Vice President, Aeromechanics Technology
Boeing Research & Technology
Author, 9/2/2015, Filename.ppt | 1
Copyright © 2015 Boeing. All rights reserved.
Boeing Research & Technology | Aeromechanics
Boeing Products
787
767
747
717
777737
C-17
F/A-18
P8
TankersPhantom Eye
V-22
Author, 9/2/2015, Filename.ppt | 2
SLS
Copyright © 2015 Boeing. All rights reserved.
Boeing Research & Technology | Aeromechanics
Increased Performance Drives Design Complexity
Mission durations from hours to days
Payloads from thousands to millions of lbs
Data from notebooks to Giga Bytes
Life from years to decadesAuthor, 9/2/2015, Filename.ppt | 3
Copyright © 2015 Boeing. All rights reserved.
Boeing Research & Technology | Aeromechanics
Complexity Increases Sustainment Needs and LCC
▪ The Comet failure in 1954 showed that static loading and a factor of safety
was not sufficient to assure safe life of a pressurized aircraft
▪ The failure of 5 B47’s with less than 2500 hours each resulted in a
disciplined aircraft structural integrity program to ensure airframe design
life requirements
▪ In 1969 an F111 failure due to a rogue manufacturing flaw illustrated a
need for a damage tolerant design and certification philosophy
Comet
Fatigue
B-47
ASIP begins
F-111
Damage Tolerance
Author, 9/2/2015, Filename.ppt | 4
Copyright © 2015 Boeing. All rights reserved.
Boeing Research & Technology | Aeromechanics
Manufacturer’s Design Requirements & Objectives
Each arrow represents a
Typical safety subject / ruleDesign
requirements
and objectives
(DR&O)
Final drawings
Regulatory standards
(FARs, JARs)
The DR&O Meets or Exceeds All Regulatory Requirements
The Final Design Meets or Exceeds the DR&O
What are the effects of change on economics and reliability?
Author, 9/2/2015, Filename.ppt | 5
Safety
Wheel
Copyright © 2015 Boeing. All rights reserved.
Boeing Research & Technology | Aeromechanics
Current Structural Maintenance and Inspection System for Commercial Airplanes
It is a regulatory requirement that operators have an approved baseline maintenance and inspection program for each airplane fleet
New technology must accommodate maintenance and inspection requirements with
the same or better reliability in a more cost effective manner
Years of service
Fleet damagerate
Environmental deteriorationand accidental damage
Corrosion inspections
Scheduled maintenance checks
Supplemental Structural inspections (MPD sec 9)
Fatigue damageStart of detectable Fatigue damage
Mandatory SB modifications and inspections
Inspection of repairs
Widespread Fatigue Damage
Author, 9/2/2015, Filename.ppt | 6
Copyright © 2015 Boeing. All rights reserved.
Boeing Research & Technology | Aeromechanics
•Reduced Redundancy
•Lower Weight/Cost
•Increased Safety
Flight Controls
•Reduced Redundancy
•Lower Weight/Cost
•Increased Safety
Flight Controls
•Reduced QA Inspections
& System Checkout Time
•Reduced Flight Test &
Certification Time & Cost
•Reduced Support
Equipment
•Reduced Initial Spares
Other
•Reduced QA Inspections
& System Checkout Time
•Reduced Flight Test &
Certification Time & Cost
•Reduced Support
Equipment
•Reduced Initial Spares
Other
•Reduced Redundancy
•Lower Weight/Cost
Avionics
•Reduced Redundancy
•Lower Weight/Cost
Avionics•Reduced Redundancy
•Increased Safety
•Lower Weight/Cost
Electrical / Wiring
•Reduced Redundancy
•Increased Safety
•Lower Weight/Cost
Electrical / Wiring
•Increased Allowables
•Lower Weight/Cost
•Increased Performance
Structures
•Increased Allowables
•Lower Weight/Cost
•Increased Performance
Structures
•Reduced Redundancy
•Improved Electrical Power
Generation Efficiency
•Increased Performance
Propulsion/APU
•Reduced Redundancy
•Improved Electrical Power
Generation Efficiency
•Increased Performance
Propulsion/APU
•Reduced Redundancy
•Lower Weight/Cost
•Increased Safety
Fuel
•Reduced Redundancy
•Lower Weight/Cost
•Increased Safety
Fuel
•Increased Allowables
•Lower Weight/Cost
•Increased Safety
Landing Gear
•Increased Allowables
•Lower Weight/Cost
•Increased Safety
Landing Gear
•Reduced Redundancy
•Lower Weight/Cost
•Increased Safety
Hydraulics
•Reduced Redundancy
•Lower Weight/Cost
•Increased Safety
Hydraulics
•Reduced Redundancy
•Lower Weight/Cost
ECS
•Reduced Redundancy
•Lower Weight/Cost
ECS
•Reduced Redundancy
•Lower Weight/Cost
•Increased Safety
Flight Controls
•Reduced Redundancy
•Lower Weight/Cost
•Increased Safety
Flight Controls
•Reduced QA Inspections
& System Checkout Time
•Reduced Flight Test &
Certification Time & Cost
•Reduced Support
Equipment
Other
•Reduced QA Inspections
& System Checkout Time
•Reduced Flight Test &
Certification Time & Cost
•Reduced Support
Equipment
Other
•Reduced Redundancy
•Lower Weight/Cost
Avionics
•Reduced Redundancy
•Lower Weight/Cost
Avionics
•Reduced Redundancy
•Increased Safety
•Lower Weight/Cost
Electrical / Wiring
•Reduced Redundancy
•Increased Safety
•Lower Weight/Cost
Electrical / Wiring
•Increased Allowables
•Lower Weight/Cost
•Increased Performance
Structures
•Increased Allowables
•Lower Weight/Cost
•Increased Performance
Structures
•Reduced Redundancy
•Improved Electrical Power
Generation Efficiency
•Increased Performance
Propulsion/APU
•Reduced Redundancy
•Improved Electrical Power
Generation Efficiency
•Increased Performance
Propulsion/APU
•Reduced Redundancy
•Lower Weight/Cost
•Increased Safety
Fuel
•Reduced Redundancy
•Lower Weight/Cost
•Increased Safety
Fuel
•Increased Allowables
•Lower Weight/Cost
•Increased Safety
Landing Gear
•Increased Allowables
•Lower Weight/Cost
•Increased Safety
Landing Gear
•Reduced Redundancy
•Lower Weight/Cost
•Increased Safety
Hydraulics
•Reduced Redundancy
•Lower Weight/Cost
•Increased Safety
Hydraulics
•Reduced Redundancy
•Lower Weight/Cost
ECS
•Reduced Redundancy
•Lower Weight/Cost
ECS
Improved
Mission
Reliability
Improved
Availability
Reduced
Life Cycle
Cost
•Reduced Redundancy
•Lower Weight/Cost
•Increased Safety
Flight Controls
•Reduced Redundancy
•Lower Weight/Cost
•Increased Safety
Flight Controls
•Reduced QA Inspections
& System Checkout Time
•Reduced Flight Test &
Certification Time & Cost
•Reduced Support
Equipment
•Reduced Initial Spares
Other
•Reduced QA Inspections
& System Checkout Time
•Reduced Flight Test &
Certification Time & Cost
•Reduced Support
Equipment
•Reduced Initial Spares
Other
•Reduced Redundancy
•Lower Weight/Cost
Avionics
•Reduced Redundancy
•Lower Weight/Cost
Avionics
•Reduced Redundancy
•Increased Safety
•Lower Weight/Cost
Electrical / Wiring
•Reduced Redundancy
•Increased Safety
•Lower Weight/Cost
Electrical / Wiring
•Increased Allowables
•Lower Weight/Cost
•Increased Performance
Structures
•Increased Allowables
•Lower Weight/Cost
•Increased Performance
Structures
•Reduced Redundancy
•Improved Electrical Power
Generation Efficiency
•Increased Performance
Propulsion/APU
•Reduced Redundancy
•Improved Electrical Power
Generation Efficiency
•Increased Performance
Propulsion/APU
•Reduced Redundancy
•Lower Weight/Cost
•Increased Safety
Fuel
•Reduced Redundancy
•Lower Weight/Cost
•Increased Safety
Fuel•Increased Allowables
•Lower Weight/Cost
•Increased Safety
Landing Gear
•Increased Allowables
•Lower Weight/Cost
•Increased Safety
Landing Gear
•Reduced Redundancy
•Lower Weight/Cost
•Increased Safety
Hydraulics
•Reduced Redundancy
•Lower Weight/Cost
•Increased Safety
Hydraulics
•Reduced Redundancy
•Lower Weight/Cost
ECS
•Reduced Redundancy
•Lower Weight/Cost
ECS
Integrated Vehicle
Health
Management
(IVHM) Solutions
IVHM Value Proposition
Improved
Operational
Plans
Efficient
Supply
Chain
Enhanced
Design
Structures is one of a number of
subsystems and must be integrated
at the system level
Author, 9/2/2015, Filename.ppt | 7
Copyright © 2015 Boeing. All rights reserved.
Boeing Research & Technology | Aeromechanics
Structural Health Management Approach
=
IMPROVED
RELIABILITY
INCREASED
PERFORMANCE
DECREASED
Life Cycle Costs
SHM is an evolution to the design process by introducing new technology and criteria that increase the structural knowledge throughout a product’s lifecycle
and therefore better predict life cycle cost drivers in time to minimize them
Structural Design
hot spot
Problem Areas
Identified
Inspection Schedule
Constructed
Analysis and Testing
737-400 Maneuver Spectra Comparison
1.00E-03
1.00E-02
1.00E-01
1.00E+00
1.00E+01
1.00E+02
1.00E+03
1.00E+04
1.00E+05
1.00E+06
-1 -0.8 -0.6 -0.4 -0.2 0 0.2 0.4 0.6 0.8 1
Incremental Vertical CG Acceleration (g's)C
um
ula
tive O
ccurr
ences p
er
1000 fli
ghts
Boeing Book 2
737 All Airplanes
+
FIRST-HAND KNOWLEDGEusage
damage
environments
Author, 9/2/2015, Filename.ppt | 8
Copyright © 2015 Boeing. All rights reserved.
Boeing Research & Technology | Aeromechanics
SHM System Design Approach to Drive Requirements that Address Decisions that Reduce LCC
Data
Collection
Data
Processing
Decision
Making &
Dissemination
Information Processing to
Define Current State
Sensors
Data
Acquisition
Hardware A1
A2
An
Data
Fusion
&
Integration
Material
StateCapability
analysis
Maintenance &
Operations
Recommendations
Visual InspectionA1, A2, An = Multiple algorithms
for SHM information processing
data information knowledge decision
NDI/NDE
Other Data
(reports of damage
events, fleet history …)
Loads and
EnvironmentsEnvironmental
State
Margins
PrognosisManufactured
State
Author, 9/2/2015, Filename.ppt | 9
…
Copyright © 2015 Boeing. All rights reserved.
Boeing Research & Technology | Aeromechanics
Quantifying AffordabilitySimplified Cost Benefit Model
Operating
benefits
NPV
Product costs
Nonrecurring
build costs
Recurring
build costs
Support
training
Weight and
power costs
Recurring
operational
cost
System
development
and design
Development
testingCertification
Software
development
Technology
development
Design
engineering
Increase
availability
Reduce
schedule
interrupts
Reduce
support costs
Reduce
maintenance
labor
Increased
Performance
Operator
introduction
Author, 9/2/2015, Filename.ppt | 10
Copyright © 2015 Boeing. All rights reserved.
Boeing Research & Technology | Aeromechanics
SHM Cash Flow is a Key Driver for AffordabilityOperational Damage Monitoring Example
▪ Increased life cycle capabilities can bring cash flow earlier into a products life cycle
▪ Incorporation as part of life cycle design
▪ Improved performance and reduced sustainment costs
▪ Manufacturing monitoring
▪ Better insight into anomalies and reduced redesign costs
Product value
Year
$
Copyright © 2015 Boeing. All rights reserved.
Boeing Research & Technology | Aeromechanics
SHM Vision
2015-2020• SHM Confidence Building
• SHM Expanded Area
Damage Detection
• SHM for Corrosion
• Multi-Scale Physics Based
Prognosis
• Virtual Life ExtensionAccidental Damage
Broad area autonomous diagnostic and
repair system as part of integrated design
Broad area
sensing
Flight parameter load monitoring
Present• NN Based Load Monitoring
• Hot Spot Damage Detection
• Bayesian Data Fusion/Prognosis
• Accidental Damage Monitoring
• Risk Enabled CBM+SI
In-Situ Fatigue Crack Monitoring Multi-Scale Material modeling and
prognostics
Real-Time Impact
monitoring
?
Diagnosis
Maintenance
Actions
Prognosis
2020+• Broad Area Diagnostics and
Diagnostics
• Identification of “Unknown
Unknowns”
• Reliability Based Design
• Bio-Inspired Sensing and Self-
Healing Materials
• Fly-by-Feel Vehicles
• Operational Mission Space
ExpansionVsink
VEαε
1
ε2 εnΦ, Φ
Author, 9/2/2015, Filename.ppt | 12
Copyright © 2015 Boeing. All rights reserved.
Boeing Research & Technology | Aeromechanics
Enhancing an Inspection Based Paradigm
Can operational usage knowledge be used to change inspection
criteria and improve design, manufacturing, and maintenance
efficiency (reduced life cycle costs) ?
CR
AC
K L
EN
GT
H
NUMBER OF
FLIGHTS
N N N N
N Based on
Design Load
Spectrum N N N N
N1 N2 N3N3N1, N2, … Based on
Operational LoadsN4
Critical crack length (allowable damage)
NDI
detectable
crack length
Crack Initiation (Durability) Crack Propagation/ Damage Tol.
Author, 9/2/2015, Filename.ppt | 13
Copyright © 2015 Boeing. All rights reserved.
Boeing Research & Technology | Aeromechanics
Copyright © 2009 Boeing. All rights reserved.
GOALS - Reduce aircraft schedule interrupts by:
1. Reducing number of falsely reported hard landings
2. Aiding the maintenance process
PHASE 2 APPROACH
• Pilot “by feel” initiated inspection
• Flight data and limited sensor information
used to predict loads
• Recommend maintenance action
• Aid maintenance procedure
AUTOMATED
LOAD PREDICTION
PHASE 1 APPROACH
• Pilot “by feel” initiated inspection
• Flight data provided
• Lookup table used to determine
maintenance action
ENHANCED MAINTENANCE INFORMATION
787 Maintenance Manual
GW < MLW+10K
Sink < 5 Sink <8
Pitch Angle <10 <10
Crab Angle <5 <3
Roll Angle <4 <2
Roll Rate <8 <4
Initial CG NZ >.9 >.95
Peak CG NZ <1.5 <2.0
CURRENT APPROACH
• Pilot “by feel” initiated inspection
• Limited flight data usage with AMM
• Large number of false positives
787 Maintenance Manual
GW < MLW
Roll Angle <2
Peak CG NZ <1.9
MAINTENANCE INFORMATION
INSPECTION
LOADS
LOAD
PREDICTION
MODEL
FLIGHT
PARAMETERS
SENSOR
DATA
LOADS
LOAD
PREDICTION
MODEL
FLIGHT
PARAMETERS
SENSOR
DATA
LOAD
PREDICTION
MODEL
FLIGHT
PARAMETERS
SENSOR
DATA
Hard Landing Detection Capability Demonstrates Basic Load Monitoring System
GOOD
BETTER
BEST
Copyright © 2015 Boeing. All rights reserved.
Boeing Research & Technology | Aeromechanics
Flight and user
demo
Multistage Approach for System V&V
6 5 4 3 2 1
14 13 12 11 10 9 8 7
24
23
6 5 4 3 2 1
14 13 12 11 10 9 8 7
23
24
15
16
17
18
19
20
21
22
19
20
21
22
WARNING: This document may contain information whose export is restricted by the Arms Export Control Act (Title 22, U.S.C. SEC 2752, et seq.) or the
Export Administration Act of 1979, as amended, Title 50, U.S.C., App 2401 et seq. This information may not be exported, released or disclosed to foreign
persons, whether in the United States or abroad, unless the export, release or disclosure is in full compliance with these statutes. Violations of these statutes
are subject to severe penalties.
C1
FACE
C2 (only for sp41)
C1 (only for sp41)
FACE
Side
Increased multi-physics and multi-scale simulation with limited testing
improves design optimization for significantly less cost and development time
Author, 9/2/2015, Filename.ppt | 15
Sensor
Actuator
Sensor
Actuator
Copyright © 2015 Boeing. All rights reserved.
Boeing Research & Technology | Aeromechanics
Weight Reduction via SHM-Enabled Design Criteria
Acoustic
Emission
DAQ
Laptop
Computer
Preamp
Coaxial cable
Impact
location
Impact generated
waves detected
n x
sensors
… n x
channels
Lead cable
Interface
panel
SHM System
SHM-based damage tolerance approach to enable significant weight savings by
reducing conservatism associated from damage uncertainty
Author, 9/2/2015, Filename.ppt | 16
Copyright © 2015 Boeing. All rights reserved.
Boeing Research & Technology | Aeromechanics
Summary of Key Challenges
DATA
• Light weight broad
area monitoring
• Relational data base
technology for
maintenance and
management
• Data mining
methods to optimize
PDF development
INFORMATION KNOWLEDGE DECISION
• Disparate source
data mining and
fusion in the context
of structural criteria
• Process based cost
modeling to assess
application benefit
• Culture:
multidisciplinary,
collaborative
optimization
methodology
• Multi-scale modeling
integrated with
monitoring
information
• Open system
architecture for
better integration of
capabilities and
knowledge
• Cradle to grave
knowledge integral
with design
optimization
• Expert system
development
coupled with DR&O
and certification
criteria development
• Open system
architecture for
platform awareness
• Decision process
integral with design
optimization in
terms of life cycle
cost optimization
Technology challenges exist at all stages of an SHM design process
Author, 9/2/2015, Filename.ppt | 17
Copyright © 2015 Boeing. All rights reserved.