SAE PT-162-2013 Integrated Vehicle Health Management Essential Reading (To Purchase Call 1-800-854-7179 USA Canada or 303-397-7956 Worldwide).pdf

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1、SAE INTERNATIONAL, Integrated Vehicle Health Management Essential Reading Edited by Ian K. Jennions Integrated Vehicle Health Management: Essential Reading PT-162.indb 1 9/18/13 2:40 PMOther SAE books of interest: Integrated Vehicle Health Management: Perspectives on an Emerging Field Edited by Ian

2、K. Jennions (Product Code: R-405) Integrated Vehicle Health Management: Business Case Theory and Practice Edited by Ian K. Jennions (Product Code: R-414) Integrated Vehicle Health Management: The Technology Edited by Ian K. Jennions (Product Code: R-429) For more information or to order a book, cont

3、act: SAE International 400 Commonwealth Drive Warrendale, PA 15096-0001 USA Phone: 877-606-7323 (U.S. and Canada only) or 724-776-4970 (outside U.S. and Canada) Fax: 724-776-0790; Email: CustomerServicesae.org; Website: books.sae.org PT-162.indb 2 9/18/13 2:40 PMIntegrated Vehicle Health Management:

4、 Essential Reading Edited by Ian K. Jennions Warrendale, Pennsylvania, USA PT-162.indb 3 9/18/13 2:40 PM Copyright 2013 SAE International eISBN: 978-0-7680-8074-2Copyright 2013 SAE International. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, distri

5、buted, or transmitted, in any form or by any means without the prior written permission of SAE International. For permission and licensing requests, contact SAE Permissions, 400 Commonwealth Drive, Warrendale, PA 15096-0001 USA; e-mail: copyrightsae.org; phone: 724-772-4028; fax: 724-772-9765. ISBN

6、978-0-7680-8067-4 Library of Congress Catalog Number 2013948307 SAE Order Number PT-162 DOI 10.4271/PT-162 Information contained in this work has been obtained by SAE International from sources believed to be reliable. However, neither SAE International nor its authors guarantee the accuracy or comp

7、leteness of any information published herein and neither SAE International nor its authors shall be responsible for any errors, omissions, or damages arising out of use of this information. This work is published with the understanding that SAE International and its authors are supplying information

8、, but are not attempting to render engineering or other professional services. If such services are required, the assistance of an appropriate professional should be sought. To purchase bulk quantities, please contact SAE Customer Service e-mail: CustomerServicesae.org phone: 877-606-7323 (inside US

9、A and Canada) 724-776-4970 (outside USA) fax: 724-776-0790 Visit the SAE International Bookstore at books.sae.org 400 Commonwealth Drive Warrendale, PA 15096-0001 USA E-mail: CustomerServicesae.org Phone: 877-606-7323 (inside USA and Canada)724-776-4970 (outside USA) Fax: 724-776-0790 PT-162.indb 4

10、9/18/13 2:40 PMv Table of Contents Introduction 1 Papers Embedded Diagnostics and Prognostics for Future Vehicles (870397), Furno, V . E., and Resnick, H. L. 11 Integrated Vehicle Health Management for Aerospace SystemsA Need for Robust and Smart Fluid Components (942167), Gormley, T. J., Vesperman,

11、 C., and Engle, J. . 19 Distributed Health Management Systems Technology for Future Propulsion Control Systems (912167), Wald, J., Schoess, J., and Hadden, G. . 31 Engines Monitoring the Progression of Micro-Pitting in Spur Geared Transmission Systems Using Online Health Monitoring Techniques (2011-

12、01-2700), Onsy, A., Shaw, B. A., and Zhang, J. 43 Very High Frequency Monitoring System for Engine Gearbox and Generator Health Management (2007-01-3878), Watson, M. J., Byington, C. S., and Behbahani, A. 59 Refinements to Mechanical Health Monitoring Algorithms (2012-01-2096), Hickenbottom, C., Kim

13、, K., and Uluyol, O. .69 Certification of Engine Health Management Systems: Guidelines for Selecting Software Assurance Levels (2011-01-2704), Rajamani, R., and Waters, N. .77 Airframes Structural Health Management: Systems Design Approach (2009-01-3230), Ihn, J-B, Davis, C., and Haugse, E. . 89 A V

14、alidation Methodology for Structural Health Monitoring (2011-01-2608), Azzam, H., and McFeat, J. 95 Ground Based Vehicle Health Monitoring for Lifecycle Cost Reduction (2003-01-2981), Schaefer, L. . 113 Smart Monitoring System for Aircraft Structures (2011-01-2714), Rouet, V ., and Foucher, B. 121 P

15、T-162.indb 5 9/18/13 2:40 PMvi Electrical Power Systems A Framework for Developing an EPS Health Management System (2010-01-1725), Hernandez, L., Mullins, M., Morris, C., and Keller, K. 129 Aircraft Electrical Power Systems Prognostics and Health Management (AEPHM) (2004-01-3162), Keller, K., Amo, A

16、. D., and Jordan, B. . 137 Integrating Electrical Prognostics and Monitoring into an Electronic Power Distribution System (2009-01-3190), Ballas, M., and Potter, F. . 149 A Model-Based Development Approach for a Diagnostic System for a Multifunctional Fuel Cell System (2011-01-2702), Modest, C., Sch

17、ories, K., Ldders, H. P ., and Thielecke, F. 157 Supporting Systems Battery Diagnostic and Prognostics for Aviation Batteries Via a Passive Diagnostic Device (2012-01-2239), James, J. E. . 167 Electrochemical Testing at SAFT to Support Health Prognostication Management for Aviation (2009-01-3191), R

18、ickman, S., Guseynov, T., Nechev, K., Kumbar, N., and Hurley, M. 173 An Overview of Electrically Powered Control Actuation Health Management (2010-01-1746), Schroeder, J. B., and Chen, R. . 179 Health Assessment of Liquid Cooling System in Aircrafts: Data Visualization, Reduction, Clustering and Cla

19、ssification (2012-01-2106), Najjar, N., Sankavaram, C., Hare, J., Gupta, S., Pattipati, K., Walthall, R., and DOrlando, P . 189 Architecture Sensory Prognostics and Management System (SPMS) (2012-01-2095), Keller, K. J., Maggiore, J., Safa-Bakhsh, R., Rhoden, W., and Walz, M. . 199 Creating a System

20、 Architecture for a Vehicle Condition-based Maintenance System (2012-01-2097), Shao, G., Goldstein, D., Kim, K., Nwadiogbu, E., Proenza, R., Tran, M., and Williams, D. . 213 A Hierarchical Reasoning Structure to Support Aerospace IVHM (2011-01-2665), Roemer, M. .223 About the Editor 231 PT-162.indb

21、6 9/18/13 2:40 PM1 1.0 Introduction Integrated Vehicle Health Management (IVHM) is a relatively new subject, with its roots back in the space sector of the early 1990s. Although many of the papers written around this timeFurno and Resnick 1987, Wald et al. 1991, and Gormley et al. 1994did not refer

22、to it as IVHM, the fun- damental principles of considering an integrated end-to-end system to monitor the overall health of the asset were clearly visible. The aspirations expressed in the early papers have been more than met by the explosion in computer and electronics technologymicroprocessors, se

23、nsors, personal computing, smart phones, the Internet, and Cloud computing, to name but a few. The speed of adop- tion of these technologies into IVHM, and the aerospace sector, has been subdued (rightly) by the need for certification, low costs, higher bandwidth, and security. Nevertheless, progres

24、s has been im- pressive and deserves recording, hence the reason for this book. 2.0 Background Many papers on IVHM and its underlying tech- nologies have been written since the mid 1990s. They have especially considered architecture, verification and validation, and certification as system ideas hav

25、e matured. These high-level considerations caused SAE International to form an IVHM Steering Group in late 2010 and, sub- sequently, an IVHM HM-1 technical group. The idea reflected the large number of groups within SAEs organization that deal with health manage- ment (HM) of systems or subsystems (

26、but without the integrated, holistic view of the vehicle asset or fleet) along with the need to write recommended practices and standards for this important area. The component SAE groups are: S-18: Aircraft and Systems Development and Safety Assessment E-32: Aerospace Propulsion Systems Health Mana

27、gement G-11: Reliability, Maintainability / Support- ability and Probabilistic Methods Group G-11 SHM: Structural Health Monitoring and Management S-12: Helicopter Powerplant AS-3: Fiber-Optics and Applied Photonics A-6: Aerospace Actuation, Control and Fluid Power Systems Steering Group AE-5: Aeros

28、pace Fuel, Oil and Oxidizer Systems Steering Group These IVHM groups have been very active, wit- nessed by: Three books on the subject; Jennions, editor 2011, 2013a, 2013b A webcast in May 2013 (http:/ /video.web- AeroTech tracks in 2011 and 2013 in IVHM A number of ARPs (Aerospace Recommend- ed Pr

29、actices) being developed To complement these activities, the current book aims to pull together the major contributions made to the field over the last 510 years, as docu- mented through SAE technical papers. 3.0 Definition and Scope Due to the work of organizations such as SAE International, the ac

30、ronym IVHM has become recognized in the aerospace sector but, because it involves the conjoining of so many different technologies, the meaning and impact on business can sometimes become unclear. For this reason, this section introduces the “modern” concept of IVHM and defines the technologies it e

31、mbraces. As this technology has grown up at the same time that businesses are making the transformation from selling a product to selling a service, it can be viewed as disruptivea relatively small technol- ogy breakthrough can be brought to market for a large business benefit. Figure 1 is a typical

32、 view of the aerospace after- market. Illustrated here is an IVHM system on the right-hand side of the figure, denoted by the sequence: senseacquiretransferanalyse act. This feeds information (processed data) on asset health into the Operations or Management control center. Here, decisions can be ma

33、de on maintenance actions to be taken with knowledge of the supply chain status, MRO loading, etc. provided from the Maintenance and Logistics systems shown at bottom left. In providing an PT-162.indb 1 9/18/13 2:40 PM2 Production, certification for example, in a military engagement, transmission ma

34、y not be possible for security reasons, and limited analysis (to maintain assets in the field) will be done in the field to give first-line maintenance actions. It is not unusual, in civil aerospace, for the transmission and analy- sis to take very little time (an hour or less), with the analysis al

35、gorithms being tuned as new data appears. Centralized analysis enables understand- ing of the fleet as well as the individual asset with planning of corrective action. This allows prob- lems seen in one or two assets of a large fleet to be closely watched in the remainder of the fleet and early inte

36、rvention taken, if necessary. To capture the technologies required to put a sequence like that shown in Figure 1 into practice, the taxonomy shown in Figure 2 has been used as a guideline to define what IVHM is, and by omission, what it is not. This taxonomy has proven extremely useful across a numb

37、er of different sectors and has withstood testing over the last five years or so.While this book could visit each of the sub- jects shown in Figure 2 sequentially, due to size constraints it is perhaps easier to categorize the technical efforts by Application, the route that has been chosen here. Hi

38、storically, engines, airframes, and electrical power systems have received the lions share of publications and will naturally be covered. However, as the field has matured, the tools and techniques have spread out to cover many areas: batteries, EMAs, and the treatment of liquid cooling systems, to

39、name just a few. Moreover, the subject of architecture, impossible Figure 1 Generic aerospace aftermarket.3 analysis, information on assets requiring attention is then transmitted to the Operations Center. It is not unusual for this whole process to take very little time (an hour or less) in actual

40、operation, with the analysis algorithms being tuned as new data appears. After the critical components of this system are distilled down, across design and operation, an IVHM taxonomy can be defined, as shown in Figure 1.3. The one presented here was produced by the IVHM Centre and has been adopted

41、by the SAE IVHM steering group. It is not intended to be all encompassing but rather to show the essential elements and how they fit together. The impetus for IVHM has been discussed above, as has some of the creation phase. The business models and their roles in leading IVHM design have been touche

42、d upon, both from the financial benefit to the company involved but also to frame the systems requirements for the design team. What is then needed in the creation phase is the systems-level thinking to bring these business requirements into a workable, and affordable, architecture. Figure 1.3 Gener

43、ic IVHM taxonomy Jennions 2011. The technologies section has been well represented for some time, but the reason that these technologies have not been put into service is due primarily to the difficulty of making a business case and the incorporation of them into an end-to-end system design. There i

44、s also a support section that without the view just discussed, has received con- siderable attention and will be used to conclude the book. These topics will now be discussed, with reference to landmark works in each field, in this order. 4.0 IVHM Progress 4.1 Engines Traditionally, gas turbine engi

45、nes have been monitored using two distinct approaches. The first looks at the oil system for signs of debris being present using Magnet Chip Detectors (MCDs) that pick up particles in the oil and provide a first sign of bearing, or other metallic, wear. The second approach monitors the gas path, wit

46、h sensors measuring temperature and pressure in strate- gic locations. These measurements are taken as snapshots at various points in the flight envelope and feed engine performance simulations that are used to assess whether they represent a healthy condition or degradation has been detected. This

47、has proven to be a simple and effective system, given that the resources are committed to main- taining the performance deck and acting on the ensuing information. From this beginning, a longer detection horizon (time from detection to failure), particularly with bearing and gear problems, was requi

48、red, and so Oil Debris Analysis (ODA) was further explored and vibration and acoustic analysis techniques were investigated. Oil Debris Monitoring (ODM) has become quite sophisticated, being able to detect a much larger proportion of the particles than MCD and with size and material information prov

49、ided on individual particles. The fuller capability of ODA was shown by Onsy et al. 2011, where they looked at micro-pitting in spur gears, backed up by vibration monitoring. An existing back-to-back gear test rig, run under strictly controlled test conditions, was used with a power transmission health monitoring system capable of measuring vibration and performing ODA. A number of new ODA indicators were de- veloped in the study, based on ferrous and nonfer- rous particles ranging in size from 40 to 30