SAE ARP 5120-2016 Aircraft Gas Turbine Engine Health Management System Development and Integration Guide.pdf

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1、_ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising there

2、from, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions. Copyright 2016 SAE International All rights reserved. No part of this p

3、ublication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-497

4、0 (outside USA) Fax: 724-776-0790Email: CustomerServicesae.orgSAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/ARP5120 AEROSPACE RECOMMENDED PRACTICE ARP5120 Issued 2016-03 Aircraft Gas Turbine

5、Engine Health Management System Development and Integration Guide RATIONALE The aviation industry uses Engine Health Management technologies to improve engine and aircraft reliability, availability and maintainability. This SAE Aerospace Recommended Practice (ARP) provides guidance on how to develop

6、 and implement an integrated end-to-end health management system for gas turbine engine applications. ARP5120 consolidates AIR1873, AIR4061B, AIR4175A, and AIR5120 into one document per the direction of the SAE E32 committee. TABLE OF CONTENTS 1. SCOPE 3 1.1 Purpose. 3 1.2 Introduction . 3 2. REFERE

7、NCES 4 2.1 Applicable Documents 4 2.1.1 SAE Publications . 4 2.1.2 Related Publications . 5 2.2 Definitions . 6 2.3 Terminology 7 3. CONCEPTS AND CONSIDERATIONS 12 3.1 Elements of Engine Health Management . 12 3.2 System Integration Considerations . 14 3.2.1 Electrical Power Integration Consideratio

8、ns . 15 3.2.2 Environmental Effects Considerations 15 3.2.3 Software Criticality Considerations . 15 3.2.4 Safety Considerations . 16 3.2.5 Cost and Benefit Considerations 16 4. RECOMMENDED PRACTICES FOR DESIGN, DEVELOPMENT, AND TEST . 17 4.1 EHM System Concept of Operations Development 17 4.2 Desig

9、ning an EHM System . 18 4.2.1 Initial User Interface Design 18 4.2.2 Design for Availability 21 4.2.3 Design for Reliability . 22 4.2.4 Design for Maintainability 22 4.2.5 Design for Safety . 23 4.2.6 System Failure Mode Effects and Criticality Analysis (FMECA) Considerations 23 4.2.7 Architecture D

10、esign . 24 4.2.8 Relevant Standards. 24 SAE INTERNATIONAL ARP5120 Page 2 of 87 4.3 System Specification - Design and Performance Requirements 24 4.3.1 System Integration 25 4.3.2 Onboard Hardware Design and Performance Requirements . 25 4.3.3 Off-Board Hardware Design and Performance Requirements .

11、28 4.3.4 Onboard and Off-Board Software Design and Performance Requirements . 31 4.3.5 Database Design . 43 4.3.6 Data Manipulation . 45 4.4 Verification and Validation (V data for trending and performance analysis; and data to assess life usage of life limited parts (LLPs). EHM adds value by provid

12、ing real time or near real time information on the functional and physical condition of a gas turbine via an Engine monitoring system (EMS). This information is used to alert operators to conditions that could impact safe operation, schedule inspections/repairs, and targeted troubleshooting to impro

13、ve functional performance, forecast spares requirements, and manage warranties. A basic concept of EHM is that data gathering and analysis be derived as much as possible through existing systems. Actual implementation of an EHM varies across customers/operators and the OEMs where an EHM system can b

14、e either fully or partially integrated into an aircraft or be dedicated to a propulsion system itself. Initial design should make use of engine variables which are primarily sensed for other purposes (e.g., engine control or flight deck display) before consideration of any additional parameters inco

15、rporated specifically for EHM. Integrating an EHM system within a platforms existing systems is dependent on several influencing factors including communication networks, signal interferences, power requirements, etc. The capabilities and technologies required to support EHM continue to be developed

16、, becoming progressively more sophisticated to meet the increasing requirements for data acquisition, storage, transfer, processing, analytics and user interface both on and off-board. This ARP describes the recommended practices for EHM throughout the engine life-cycle including: x Conception x Des

17、ign and Development (Specification, Hardware and Software Build, Verification and Validation) x Training and Entry into Service (EIS) x Sustaining Support (Maintenance, Error Correction, Systems Enhancements, De-Commissioning) SAE INTERNATIONAL ARP5120 Page 4 of 87 ARP4754 provides foundational guid

18、ance for designing and developing EHM system support hardware and software installed on the air vehicle. In addition, other available documents, such as RTCA DO-178, which provides guidance to the development of EHM software, and RTCA DO-248, which provides supporting guidance to RTCA DO-178. Howeve

19、r, RTCA DO-178 does not specifically address the unique characteristics of ground based EHM software. As of the issuance of this document, there are activities underway within SAE to address this aspect. This ARP identifies, as applicable, additional or alternative development guidance for onboard h

20、ardware and software systems as well as off-board systems. This ARP also provides guidance for the development of the supporting infrastructure required for these ground-based functions. The guidance of this ARP applies to an EHM system implemented on a new platform or for retrofit on a legacy appli

21、cation. When applying the guidelines of this ARP it should be noted that engine monitoring systems may be physically or functionally integrated with the engine control system and may also affect safety or be used to effect continued operation or return to service. For any decision to apply the guide

22、lines of this ARP, the decisions shall be subject to the Type Investigation of the product in which they will be incorporated and must show compliance with the applicable airworthiness requirements as defined by the responsible Aviation Authority. This is not limited to but includes the application

23、of software levels consistent with the criticality of the performed functions. For instance, Low Cycle Fatigue (LCF) cycle counters for safety critical parts would be included in the Type Investigation but most trend monitors and devices providing information for economically based maintenance decis

24、ions would not. 2. REFERENCES 2.1 Applicable Documents The following publications form a part of this document to the extent specified herein. The latest issue of SAE publications shall apply. The applicable issue of other publications shall be the issue in effect on the date of the purchase order.

25、In the event of conflict between the text of this document and references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained. 2.1.1 SAE Publications Available from SAE I

26、nternational, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or +1 724-776-4970 (outside USA), www.sae.org. ARP1587 Aircraft Gas Turbine Engine Health Management System Guide ARP4102 Flight Deck Panels, Controls, and Displays ARP4176 Determination of Cos

27、ts and Benefits from Implementing an Engine Health Management System ARP4754 Certification Considerations for Highly Integrated or Complex Aircraft Systems ARP4761 Guidelines and Methods for Conducting the Safety Assessment Process on Civil Airborne Systems and Equipment ARP5783 Health and Usage Mon

28、itoring Metrics, Monitoring the Monitor ARP6275 Determination of Cost Benefits from Implementing an Integrated Vehicle Health Management System AS8034 Minimum Performance Standard for Airborne Multipurpose Electronic Displays R-405.SET3 Jennions, I.K., “IVHM/Integrated Vehicle Health Management 3-Bo

29、ok Set,” (Warrendale, SAE International, 2013), ISBN 978-0-7680-8101-5 SAE INTERNATIONAL ARP5120 Page 5 of 87 2.1.2 Related Publications The following publications are provided for information purposes only and are not a required part of this SAE Aerospace Technical Report. ADS-37 Aeronautical Desig

30、n Standard for Electromagnetic Environmental Effects Performance and Verification Requirements ADS-79 Aeronautical Design Standard Handbook, Condition Based Maintenance System for US Army Aircraft ANSI/EIA-649 American National Standard Institute, Configuration Management Standard ANSI/EIA-836 Ameri

31、can National Standard Institute, Configuration Management Data Exchange and Interoperability GEIA-HB-649 Government Electronics (2) Allows each layer to provide a set of accessible functions that can be controlled and used by the functions in the layer above it; (3) Enables each layer to be implemen

32、ted without affecting the implementation of other layers; (4) Allows the alteration of system performance by the modification of one or more layers without altering the existing equipment, procedures, and protocols at the remaining layers. POWER ASSURANCE: The measurement and interpretation of the e

33、ngine data to determine whether sufficient power or thrust will be delivered by the engine within mission operating limits. POWER SETTING (PS) PARAMETER: That parameter used by the engine manufacturer to determine engine power or thrust. Various parameters are used for this purpose (for example, EPR

34、, Torque, N1, etc.). PROGNOSTICS: EMS functions that address the detection and/or isolation of future component failures, degradation, etc., before that failure or deterioration causes the engine to fail to perform its intended function. The forecast can be expressed as remaining useful life (RUL),

35、or time to reach a specific degradation level, or time to reach a point at which the risk of component failure is unacceptable. TRENDING: Utilization of a backward looking time scale incorporating parametric data to detect deviations from historical or expected data. 2.3 Terminology AC Alternating C

36、urrent or Advisory Circular ACARS Aircraft Communication Addressing and Reporting System A/D Analog to Digital ADR Accident Data Recorder AIR Aerospace Information Report AIRCOM Air to Ground Communication SAE INTERNATIONAL ARP5120 Page 8 of 87 ALE Application Level Events API Application Programmin

37、g Interface APU Auxiliary Power Unit ARINC Aeronautical Radio Incorporated ARP Aerospace Recommended Practice AS Aerospace Standard ASD Aerospace and Defence Industries Association of Europe BIT Built-In-Test BITE Built-in Test Equipment BOD Business Object Document B2B Business to Business B2MML Bu

38、siness to Manufacturing Markup Language CAD/CAM Computer Aided Design/Computer Aided Manufacturing CAS Calibrated Air Speed CBA Cost Benefits Analysis CDF Common Data Format CFR Code of Federal Regulations CI Condition Indicator CMC Central Maintenance Computer CNS/ATM Communication, Navigation, Sur

39、veillance and Air Traffic Management CONOPS Concept of Operations COTS Commercial off the Shelf CRC Cyclic Redundancy Check or Cyclic Redundant Code CSV Comma Separated Values CPU Central Processing Unit D/A Digital to Analog DAL Design Assurance Level DEX Data Exchange DFM Design for Maintainabilit

40、y SAE INTERNATIONAL ARP5120 Page 9 of 87 DFR Design for Reliability DSP Digital Signal Processor DTD Data Transfer Device DVD Digital Versatile Disc EASA European Aviation Safety Authority ECU Engine Control Unit EEC Electronic Engine Controller EEPROM Electronically Erasable Programmable Read Only

41、Memory EGT Exhaust Gas Temperature EMS Engine Health Management System EIS Entry Into Service EMC Electro-Magnetic Compatibility EMI Electro-Magnetic Interference EMS Engine Monitoring System EPR Engine Pressure Ratio EPROM Electronic Program Read Only Memory ERFE External Radio Frequency Environmen

42、t FAA Federal Aviation Administration FADEC Full Authority Digital Engine Control FDR Flight Data Recorder FFT Fast Fourier Transformation FHA Functional Hazard Assessment FMEA Failure Modes Effects Analysis FMECA Failure Modes Effects and Criticality Analysis FOQA Flight Operations Quality Assuranc

43、e HDF Hierarchical Data Format HI Health Indicator HIRF High Intensity Radiated Fields ICD Interface Control Document SAE INTERNATIONAL ARP5120 Page 10 of 87 IEC International Electro technical Commission IEEE Institute of Electrical and Electronic Engineers IETM Integrated Electronic Technical Manu

44、al ILS Integrated Logistics Support IRIG Inter-Range Instrumentation Group ISA International Standard Atmosphere ISO International Standards Organization IVHM Integrated Vehicle Health Management LCC Life Cycle Cost LCF Low Cycle Fatigue LLP Life Limited Parts LSAR Logistic Support Analysis Record L

45、RU Line Replaceable Unit MD5 Message Digest version 5 MGT Mean Gas Temperature MIMOSA Machinery Information Management Open Systems Alliance MOS Management Operating System MRO Maintenance Repair and Overhaul MTBR Mean Time Between Removal N1, N2 Engine Spool Speeds OAGIS Open Applications Group Int

46、egration Specification OCR Optical Character Recognition OEM Original Equipment Manufacturer OSA-CBM Open System Architecture for Condition Based Maintenance OSA-EAI Open System Architecture for Enterprise Application Integration OWL Web Ontology Language PC Personal Computer PCM-CIA Personal Comput

47、er Memory Card International Association P-F Potential to Failure SAE INTERNATIONAL ARP5120 Page 11 of 87 PLCS Product Life Cycle Support PLM Product Lifecycle Management PMA Portable Maintenance Aid POD Probability of Detection PPI Power Performance Index PROM Programmable Read Only Memory PSAC Pla

48、n for Software Aspects of Certification QAR Quick Access Recorder RAM Random Access Memory RFID Radio Frequency Identification ROI Return on Investment ROM Read Only Memory RPM Revolutions per Minute RTCA Radio Technical Commission for Aeronautics RTO Research and Technology Organization RUL Remaini

49、ng Useful Life SAT Static Air Temperature SATAA Sense, Acquire, Transfer, Analyze, Act SD Secure Digital card SHP Shaft Horse Power SIL Systems Integration Laboratory SITA Socit Internationale de Tlcommunications Aronautiques communications provider SLOATL Sea-Level, Outside Air Temperature Limit STEP Standard for the Exchange of Product TAT Total Air Temperature TLA Throttle Lever Angle TSA Technical Service Agreement UER Unsch