F-35 Joint Strike Fighter Structural Prognostics and Health Management An Overview

Size: px

Start display at page:

Download "F-35 Joint Strike Fighter Structural Prognostics and Health Management An Overview"

Camron Watson
5 years ago
Views:

Program Office Devinder Mahal - JSF Program Office

1 F-35 Joint Strike Fighter Structural Prognostics and Health Management An Overview Tim Fallon - JSF Program Office Devinder Mahal - JSF Program Office Iain Hebden BAE Systems 2009 ICAF Conference. Rotterdam

2 Air Vehicle Service Life Ninety percent of all delivered JSF Air Vehicles, by variant, shall achieve either 30 years of operation or 8000 flight hours 2

3 3

4 Overview Enterprise Health Management SPHM Goals System Overview Air Vehicle Off Board Fleet Management DISTRIBUTION DISTRIBUTION STATEMENT STATEMENT A: Approved A: Approved for Public for Public Release: Release: Distribution Distribution Unlimited is Unlimited 4

5 PHM a design attribute of a JSF JSF is committed to reducing O&S costs Legacy is unaffordable! R&D and Production O&S R&D and Production O&S TODAY JSF JSF is committed to not doing business as usual A supportable and affordable next generation fighter needs. A Highly Supportable, State of the Art Prognostics and Health Management (PHM) System Lethal Survivable Supportable Affordable 5

. Structural Prognostics and Health Management (SPHM) PHM Architecture Air Vehicle On-Board Health Assessment Air Vehicle/Support System Interface Auto Log & Off-Board PHM Fault Accommodation Status

Logistics Enabling/Interface NVM Mission Critical PHM Data Crash Recorder AMD/PMD PVI Displays and Controls Portable Memory Device (PMD) Results In: Decision Support Maintenance Planning

6 . Structural Prognostics and Health Management (SPHM) PHM Architecture Air Vehicle On-Board Health Assessment Air Vehicle/Support System Interface Auto Log & Off-Board PHM Fault Accommodation Status via ICAWS PHM Area Managers Hosted in ICP Flight Critical Provides: AV-Level Info Management Intelligent FI Prognostics/Trends Auto. Logistics Enabling/Interface NVM Mission Critical PHM Data Crash Recorder AMD/PMD PVI Displays and Controls Portable Memory Device (PMD) Results In: Decision Support Maintenance Planning Condition-Based Maint. Efficient Logistics Airframe Mission Systems Vehicle Systems Propulsion PHAM Methods Used: Sensor Fusion Model-Based Reasoning Tailored Algorithms Systems Specific Logic / Rules Feature Extraction AVPHM Hosted in ICP Maintainer Vehicle Interface Fault/Service Info PMA In-Flight Data Link Maintenance Panel IETMs Consumables On-Board Diagnostics ALIS Automated Pilot/ Maint. Debrief Off-Board Prognostics Trending Life Mgmt Intelligent Help Store/Distribute PHM Information Database 6

SPHM Goals Minimize maintenance while maintaining safety Eliminate scheduled inspections - Goal is on-condition maintenance Achieve condition based maintenance at minimum cost Individual aircraft

7 SPHM Goals Minimize maintenance while maintaining safety Eliminate scheduled inspections - Goal is on-condition maintenance Achieve condition based maintenance at minimum cost Individual aircraft tracking Fully automated Support structural prognostics Minimize dedicated SPHM sensors SPHM integral part of AVPHM and OBPHM Capability to accept emerging technologies DISTRIBUTION DISTRIBUTION STATEMENT STATEMENT A: Approved A: Approved for Public for Public Release: Release: Distribution Distribution Unlimited is Unlimited 7

8 SPHM Capabilities Air Vehicle SPHM Capability Recording of raw PHM data Structural Events (Overloads) Structural Usage Indices Aircraft Parameters Control surface usage Door usage Landing data Corrosion Environment Sensing OBPHM SPHM Planned Capability Individual Aircraft Tracking Fatigue life consumption at selected critical locations. Remaining life estimate for maintenance and operational planning Corrosion prediction & tracking models Fleet management, lead aircraft, identification of damaging manoeuvres. Usage compared to design spectra Flight event replay Loads/Environment Spectra Survey (L/ESS) - PHM related data Data mining maintenance, repair, manufacturing history, usage indices 8

9 SPHM Functions Operational Loads Measurement Strain gage Parametric models Safe-Life and Damage Tolerant models Structural Overload Measurement Auxiliary Structural Data collection Corrosion Environment Monitoring 9

Sill LH Vertical Tail Bending Attachment Centre Fuselage Bending LH Aft Fuselage

10 SPHM Strain Sensor Locations (STOVL) Mirrored Locations SPHM Strain Sensor LH Vertical Tail Shear Attachment LH Aft Fuselage Actuator Lug Forward Fuse Canopy Sill LH Vertical Tail Bending Attachment Centre Fuselage Bending LH Aft Fuselage Kicked Keel Wing Root LH Shear Wing Root LH Bending Wing Root BH 496 Flaperon Hinge Attach 10

11 Strain Sensors JSF philosophy strain sensors are for model development, verification and refinement All Strain Sensors are in baseline design and would require an engineering change to remove them. Full Bending and Shear Bridges. One side of aircraft instrumented Other side validated with loads aircraft instrumentation Can be in difficult to access locations Primary and Backup gages Will not be maintained operate until they expire All aircraft will be tracked primary means is parametric equations and dynamic models Tag Strip σ2 τ1 τ2 σ1 P+ P- S+ S- B Cable - Twisted Shielded pair Multi core Shielded Splice 11

Strain Sensors JSF philosophy strain sensors are for model development, verification and refinement All Strain Sensors are in baseline design and would require an engineering change to remove them.

12 Strain Sensors JSF philosophy strain sensors are for model development, verification and refinement All Strain Sensors are in baseline design and would require an engineering change to remove them. Full Bending and Shear Bridges. One side of aircraft instrumented Other side validated with loads aircraft instrumentation Can be in difficult to access locations Primary and Backup gages Will not be maintained operate until they expire All aircraft will be tracked primary means is parametric equations and dynamic models σ2 τ1 τ2 σ1 Tag Strip - + Tension P+ P- S+ Gauge 1 P S- B Monitored and recorded at 320 Hz. Time Synched. Gauge 2 Compression 12

13 Sensor 1 LH Vertical Tail Attachment FS 575 Indicative Positions of Strain Gauges 13

14 Sensor 2 LH Vertical Tail Attachment FS 609 Primary Bridge Backup Bridge Indicative Positions of Strain Gauges Frame 609 LH Side View Looking Outboard Frame 609 LH Side View Looking Inboard backup primary backup primary 14

15 Sensors 3 LH Aft Fuselage Kicked Keel FS 625 Indicative Positions of Strain Gauges 15

16 Sensors 4 LH Aft Fuselage Kicked Keel FS 625 Indicative Positions of Strain Gauges UP Tag Strip AFT 16

17 Sensors 5&6 LH Wing Carry Thru Bulkhead UP OUTBOARD Tag Strip

18 Sensor 7 LH Wing Rear Spar FS550 Indicative Positions of Strain Gauges

19 Sensor 8 RH Canopy Sill FS244 Indicative Position of Strain Gauges Canopy Sill Longeron, RH Canopy Latch Fitting Primary Backup View Looking Inbd and Up at RHS (For Orientation Purposes) UP FORWARDS 19

20 Sensor 9 LH Wing Carry Thru Bulkhead 496 Sensor 9 Location 20

21 SPHM Sensor 10 - Centre Fuselage Bending 21

22 RIO to Sensors Wiring Routes VS Network Strain Sensors common to all three a/c variants RIO (VSP) Fully Shielded Wire. Note: Cable runs not representative RIO #2 (B & C) RIO #4 (B) RIO #4 (C) 8 9 Strain Gauge Identification Key 1. LH Vertical Tail Attachment - (mid spar lower lug) 2. LH Vertical Tail Attachment - (rear spar lower lug) 3. LH Horizontal Tail - (actuator horn) RIO #3 (A, B, & C) LH Horizontal Tail - (hinge spar) 5. LH Wing Root - (Frame 450 bending) 6. LH Wing Root - (Frame 450 Shear) 7. LH WR Rear bulkhead RIO #4 (A) 10 RIO #1 (A & B) 8. Canopy Sill 9. Centre Fuselage Bending 10. Flaperon Attach 22

RIO interface JSF RIO Specification of System Requirements V s Remote Input Output Device V X V + V 12 bit ADC Processing Range of V= ±100mV Range of V x

23 RIO interface JSF RIO Specification of System Requirements V s Remote Input Output Device V X V + V 12 bit ADC Processing Range of V= ±100mV Range of V x = 0-10V V/V X RIO Scaling Value =( V/V X )*10000 Range=±100 Bus Message l.s.b = Integer Value - Range ±1000 V - For a Full Poisson Bridge Circuit: 23

Aircraft Parameters Over 100 parameters monitored AND RECORDED continuously 320 Hz Strain data, written as 4 words per 80 Hz record 80 Hz linear inertial data 20 Hz air data, control surface, door,

24 Aircraft Parameters Over 100 parameters monitored AND RECORDED continuously 320 Hz Strain data, written as 4 words per 80 Hz record 80 Hz linear inertial data 20 Hz air data, control surface, door, engine parameter, etc 1 Hz on discretes Recorded from BF-1 and on Initial estimate is ~200 MB per flight hour Expect <100 MB / hr at end of SDD Additional data compression possible both on and off board DISTRIBUTION DISTRIBUTION STATEMENT STATEMENT A: Approved A: Approved for Public for Public Release: Release: Distribution Distribution Unlimited is Unlimited 24

25 Aircraft Parameters Inertia and Strain Sensor Data Parameter Minimum Sample Rate per second Longitudinal Acceleration at the Centre of Gravity 80 Lateral Acceleration at the Centre of Gravity 80 Normal Acceleration at the Centre of Gravity 80 Measured Longitudinal Load Factor (Nx) 80 Measured Lateral Load Factor (Ny) 80 Measured Normal Load Factor (Nz) 80 Rationale Notes Measured value at Centre of Gravity not available. Translation to be perfomed offboard Measured value at Centre of Gravity not available. Translation to be perfomed offboard Measured value at Centre of Gravity not available. Translation to be perfomed offboard Body Axis X Angular Acceleration 20 Body Axis Y Angular Acceleration 20 Body Axis Z Angular Acceleration 20 Roll Rate 20 Pitch Rate 20 Yaw Rate 20 Roll Attitude 20 Pitch Attitude 20 Heading 20 Yaw attitude not available as a specfic parameter Body Axis X Velocity 20 Body Axis Y Velocity 20 Body Axis Z Velocity 20 Strain sensor values CTOL (10) 320 Strain sensor values STOVL (10) 320 Strain sensor values CV (13)

26 Air Data Aircraft Parameters Parameter Minimum Sample Rate per second Angle of Attack 20 Static Pressure Measured 20 Total Pressure Measured 20 Angle of Sideslip 20 Air Density Ratio 20 Baro Setting 20 Pressure Altitude 20 Baro Reference Altitude 20 Altitude Rate 20 Mach Number 20 Pressure Ratio 20 Dynamic Pressure 20 Impact Pressure 20 True Freestream Air Temperature 20 Total Temperature 20 Calibrated Airspeed 20 Equivalent Airspeed 20 True Airspeed 20 26

27 Mass Data Weight of empty aircraft Parameter Aircraft Parameters Minimum Sample Rate per second Aircraft BL Centre of Gravity Position 80 Aircraft WL Centre of Gravity position 80 Aircraft FS Centre of Gravity position 80 Store Quantities Stations 1 to 12 On Change Store Type Stations 1 to 12 On Change Rack Type Stations 1 to 12 On Change Ejector Type Station 1 to 12 On change Max Fuel for each Tank 1 Min Fuel for each Tank 1 Miscellaneous Data Rationale Notes Aircraft gross weight to be calcualted offboard using basic weight, expendables and consumables data Stores mass to be calculated offboard Simulated store is accounted for in stores data. Tanks F1, F2L, F2R, F3L, F3R, F4L, F4R, F5L, F5R, LW, RW, ELW, ERW Tanks F1, F2L, F2R, F3L, F3R, F4L, F4R, F5L, F5R, LW, RW, ELW, ERW Parameter Minimum Sample Rate per second Rationale Notes Radar Altimeter 1 Source of accurate low level altitude data STOVL Mode 20 Track 1 True Heading 1 Vertical Velocity 1 Velocity East 1 Velocity North 1 27

28 Aircraft Parameters Control Surface, Doors and Canopy Parameter Minimum Sample Rate per second Left Aileron Angular Position (CV) 20 Right Aileron Angular Position (CV) 20 Left Flaperon Angular Position 20 Right Flaperon Angular Position 20 Left Horizontal Tail Angular Position 20 Right Horizontal Tail Angular Position 20 Left LEF Angular Position 20 Right LEF Angular Position 20 Left Outboard LEF Angular Position (CV) 20 Right Outboard LEF Angular Position (CV) 20 Left Vertical Tail Angular Position 20 Right Vertical Tail Angular Position 20 Canopy Enumerated Position 1 Landing Gear Door Enumerated Positions 1 STOVL Door Enumerated Positions 1 Weapon Bay Door Enumerated Positions (Inboard Left, Outboard Left, Inboard Right, Outboard Right) 20 Weapon Bay Door Angular Positions (Inboard Left, Outboard Left, Inboard Right, Outboard Right) 20 Refuel Receptacle Door Enumerated Positions 1 Refuel Probe Door Enumerated Positions 1 28

29 Aircraft Parameters Landing, Launch and Arresting Gear Parameter Minimum Sample Rate per second Left Main Landing Gear Enumerated Position 1 Right Main Landing Gear Enumerated Position 1 Nose Landing Gear Enumerated Position 20 Left Main Landing Gear Weight on Wheels 20 Right Main Landing Gear Weight on Wheels 20 Nose Landing Gear Weight on Wheels 20 Left Main Landing Gear Wheel Speed 20 Right Main Landing Gear Wheel Speed 20 Nose Landing Gear Wheel Speed 20 Launch Bar Up 1 Launch Bar Down 1 Launch Bar Brakes 1 Arrestor Gear Retracted 1 Arrestor Gear Deployed 1 Cockpit Parking Brake Engaged/Not Engaged 1 29

30 Engine Data Aircraft Parameters Parameter Minimum Sample Rate per second Estimated Total Gross Thrust Feedback 20 Estimated Main Nozzle Thrust 20 Main Engine Core Speed 20 Main Engine Fan Speed 20 Main Engine Core Speed - Physical (%) 20 Main Engine Fan Speed - Physical (%) 20 Ready to Convert to Jet 20 Ready to Convert to Wing 20 Thrust Split Achieved 20 Lift Fan Nozzle Pitch Angle Position 20 3BSD Pitch Angle Position 20 3BSD Yaw Angle Position 20 Longitudinal Thrust Split Feedback 20 Roll Post Thrust Split Feedback 20 Estimated Left Roll Nozzle Thrust Feedback 20 Estimated Right Roll Nozzle Thrust Feedback 20 Estimated Lift Fan Thrust 20 Lift Fan Speed - Physical 20 Lift Fan Speed - RPM 20 Lift Fan / Clutch Status Word 20 30

roll rate Add: Hard landing & Over speed Add: ICAWS End of SDD Update to Overload Off Board Monitor loads at key

31 Overload Monitoring CER/CEA/CEM Conditional Event Reporting, Analysis and Maintenance Health Reporting Code generated Air Vehicle Initial Interim Overload tracking Nz vs. roll rate Add: Hard landing & Over speed Add: ICAWS End of SDD Update to Overload Off Board Monitor loads at key locations Target specific inspections New process ATLAS Loads approach Quality controlled and corrected/verified signals Overload analysis and display Maintenance Action generated 31

Usage/Auxiliary Data Collection Usage data tables accumulated onboard the air vehicle Prevents against data loss and provides comparison to design In segregated memory not overwritten Occurrence and

32 Usage/Auxiliary Data Collection Usage data tables accumulated onboard the air vehicle Prevents against data loss and provides comparison to design In segregated memory not overwritten Occurrence and Time accumulation Additional System Health check Additional Calculated loads peak/valley tables DISTRIBUTION DISTRIBUTION STATEMENT STATEMENT A: Approved A: Approved for Public for Release: Public Release: Distribution Distribution Unlimited is Unlimited 32

33 Auxiliary Data Life Cumulative Flight-byflight Max number of flights stored before overwrite Storage Method for Usage Data Altitude Monitoring Time at Mach-Altitude by Gross Weight Band X 10 Attitude Monitoring Time at AoA-Dynamic Pressure-Side slip by Mach No X 10 Cockpit Pressurisation Cockpit Pressurisation Cycle Count X 10 Pressure-Altitude From-To Spectrum X 10 Control Surface Movement Flaperon Movement X 10 Rudder Movement X 10 Horizontal Tail Movement X 10 Speed Brake Deployment Count X 10 Time in Speed Range for Speed Brake Deployment X 10 On Ground Monitoring Canopy Cycle Count X N/A Landing Gear Cycle count in Maintenance Mode X N/A In-Flight Door Opening Weapon Bay Door Cycles X N/A Weapon Bay Door Open Time in Speed Range X N/A Refuel Receptacle Door Cycles X N/A Refuel Receptacle Door Open Time in Speed Range X N/A STOVL Door Cycles X N/A Refuel Probe Door Cycles (STOVL) X N/A Refuel Probe Door Open "Time in Speed Range" X N/A In-Flight Landing Gear Cycles Landing Gear Cycle count in air X N/A In-Flight Occurrence Spectra LESS Flight Spectra Ny X 10 Nz X 10 p X 10 pdot X 10 IAT Flight Spectra Nz X 10 Nz*W X 10 33

34 Auxiliary Data In-Flight Refuel Monitoring Storage Method for Usage Data Life Cumulative Flight-byflight Max number of flights stored before overwrite No of In-flight Refuels (CTOL) X N/A No of Boom Contacts (CTOL) X N/A No of In-flight Refuels (Probe) (STOVL) X N/A In-Flight Severity Index Spectra IAT Severity Indices (Peak-Valley format) Forward Fuselage Severity Index (CTOL, STOVL) X 10 Wing Root Severity Index (CTOL, STOVL) X 10 Wing Mid-Span to Tip Severity Index (CTOL, STOVL) X 10 Horizontal Tail Severity Index (CTOL, STOVL) X 10 Centre Forward/Aft Fuselage (CTOL, STOVL) X 10 Vertical Tail Severity Index (CTOL, STOVL) X 10 IAT Severity Indices (From-To format) Forward Fuselage Severity Index (CTOL, STOVL) X 10 Wing Root Severity Index (CTOL, STOVL) X 10 Wing Mid-Span to Tip Severity Index (CTOL, STOVL) X 10 Horizontal Tail Severity Index (CTOL, STOVL) X 10 Centre Forward/Aft Fuselage (CTOL, STOVL) X 10 Vertical Tail Severity Index (CTOL, STOVL) X 10 Takeoff and Landing Monitoring Conventional Takeoff by Gross Weight Band X 10 Vertical Takeoff by Gross Weight Band (STOVL) X 10 Rolling Vertical Takeoff by Gross Weight Band (STOVL) X 10 Conventional Landing by Gross Weight Band X 10 Vertical Landing by Gross Weight Band (STOVL) X 10 Rolling Vertical Landing by Gross Weight Band (STOVL) X 10 Touch and Go Landing by Gross Weight Band X 10 Landing Load Special Event X 10 34

35 Sample From/To Table From "To" Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < 11.0 Nz > 11.0 Nz Band No. Nzcg Band (g's) 1 Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < 0.0 Occurrences < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < < Nz < Nz >

36 Time at Mach/Altitude Sample Time at Event Table Altitude Band (feet) Mach No Band M < < M < < M < < M < < M < < M < < M < < M < < M < < M < < M < < M < < M < < M < < M < < M < < M < < M < < M < 1.9 M>1.9 1 h < 2K 2 2K < h < 4K 3 4K < h < 6K 4 6K < h < 8K 5 8K < h < 10K 6 10K < h < 12K 7 12K < h < 14K 8 14K < h < 16K 9 16K < h < 18K 10 18K < h < 20K Count 11 20K < h < 22K 12 22K < h < 24K 13 24K < h < 26K 14 26K < h < 28K 15 28K < h < 30K 16 30K < h < 35K 17 35K < h < 40K 18 40K < h < 45K 19 45K < h < 50K 20 h > 50K 36

37 Example Calculated Load From/To WRBM Band No From WRBM Band (in-lb) "To" WRBM <-4000K -4000K < WRBM <-3500K -3500K < WRBM <-3000K -3000K < WRBM <-2500K -2500K < WRBM <-2000K -2000K < WRBM <-1500K -1500K < WRBM <-1000K -1000K < WRBM <-500K -500K < WRBM < 0K 0K < WRBM < 500K 500K < WRBM < 1000K 1000K < WRBM < 1500K 1500K < WRBM < 2000K 2000K < WRBM < 2500K 2500K < WRBM 3000K 3000K < WRBM < 3500K 3500K < WRBM < 4000K 4000K < WRBM < 4500K 4500K < WRBM < 5000K 5000K < WRBM < 5500K 5500K < WRBM < 6000K 6000K < WRBM < 6500K 6500K < WRBM < 7000K 7000K < WRBM < 7500K 7500K < WRBM < 8000K 8000K < WRBM < 8500K 8500K < WRBM < 9000K WRBM > 9000K 1 WRBM <-4000K K < WRBM <-3500K K < WRBM <-3000K K < WRBM <-2500K K < WRBM <-2000K K < WRBM <-1500K K < WRBM <-1000K K < WRBM <-500K 9-500K < WRBM < 0K Occurrences 10 0K < WRBM < 500K K < WRBM < 1000K K < WRBM < 1500K K < WRBM < 2000K K < WRBM < 2500K K < WRBM < 3000K K < WRBM < 3500K K < WRBM < 4000K K < WRBM < 4500K K < WRBM < 5000K K < WRBM < 5500K K < WRBM < 6000K K < WRBM < 6500K K < WRBM < 7000K K < WRBM < 7500K K < WRBM < 8000K K < WRBM < 8500K K < WRBM < 9000K 28 WRBM > 9000K 37

Corrosion Sensors Replace scheduled inspections with on

aircraft Demonstrate reliability and refine models Growth

value locations chosen Sentinel Resistance sensors

begin to corrode Tied into aircraft bus to automatically

38 Corrosion Sensors Replace scheduled inspections with on condition inspections Sensors in 2 locations on SDD aircraft Demonstrate reliability and refine models Growth capability exists as needs emerge Difficult access, high value locations chosen Sentinel Resistance sensors Resistance changes as pre-calibrated strips on sensor begin to corrode Tied into aircraft bus to automatically record data at start and end of flight UP Aft Sensor 14 (Type A) Sensor 15 (Type B) 38

39 Scenario 1 Sensor output corresponds with inspection data Corrosion Sensor reports corrosion in same timeframe that inspection reveals corrosion Corrosion repaired Replacement sensor installed Aged or new? Need to understand quality of repair against original coatings. Validation evidence requires suitable sample Sensor slot widths suitable 84 day inspection 84 day inspection 84 day inspection 84 day inspection 84 day inspection 84 day inspection 84 day inspection 84 day inspection No corrosion Corrosion found Inspection Sensor Output Corrosion repaired. New Sensor Installed First slot depleted 39

SPHM Capabilities Air Vehicle SPHM Capability Recording of raw PHM data Structural Events (Overloads) Structural Usage Indices Aircraft Parameters Control surface usage Door usage Landing data

40 SPHM Capabilities Air Vehicle SPHM Capability Recording of raw PHM data Structural Events (Overloads) Structural Usage Indices Aircraft Parameters Control surface usage Door usage Landing data Corrosion Environment Sensing Aircraft Configuration OBPHM SPHM Planned Capability Individual Aircraft Tracking Fatigue life consumption at selected critical locations. Remaining life estimate for maintenance and operational planning Corrosion prediction & tracking models Fleet management, lead aircraft, identification of damaging manoeuvres. Usage compared to design spectra Flight event replay Loads/Environment Spectra Survey (L/ESS) - PHM related data Data mining maintenance, repair, manufacturing history, usage indices 40

Individual Aircraft Tracking SPHM Operational Loads Monitoring (OLM) SPHM Area Manager Fed Various Flight Parameters Most Data Sources SOF Time History Captured Parameter Cycle

Future updates are table driven, not OFP changes Requirement for 98% Accurate data collection M n z p δ HT σ i Time Cycle σ m ε a 1 xxxx yyyy 2 xxxx yyyy.

41 Individual Aircraft Tracking SPHM Operational Loads Monitoring (OLM) SPHM Area Manager Fed Various Flight Parameters Most Data Sources SOF Time History Captured Parameter Cycle Counting and Usage Statistics Calculated by SPHM Area Manager Fatigue Life Expended for Control Points Tracked Results stored for ALIS download and further force life management Future updates are table driven, not OFP changes Requirement for 98% Accurate data collection M n z p δ HT σ i Time Cycle σ m ε a 1 xxxx yyyy 2 xxxx yyyy. n xxxx yyyy Individual Aircraft Usage Exceedances Altitude n z W Time MT y it Mach t j MT x Individual Aircraft Damage σ σ N ε Control Point t k Damage Index n J /3/99

42 IAT Fatigue Damage Calculation Flight Parameters Strain Sensors Parameter to Loads Models Strain Sensor Replication Models Strain External Loads Internal Loads *Damage model for IAT tracking uses same model as design Damage Tolerance for CTOL Initiation Strain Life STOVL and CV Stress *Damage Config/look-up table. - Allows system to be built in advance of final algorithm definition 42

ALIS Conops ALGS Kit Central Services Kit Base and

Servers (GBCU) OMSE OMS WS GDR Support ALGS Ops and

Information Flow between Military & Commercial Networks

43 ALIS Conops ALGS Kit Central Services Kit Base and Squadron Kit PCA ALOU (Servers) CPE (Servers) PMA SOU Servers (GBCU) OMSE OMS WS GDR Support ALGS Ops and provide operational data to support PBL management Control Information Flow between Military & Commercial Networks Support Squadron Activities Operations & Maintenance Pre- and Post-Mission 43

SPHM Health Management Screens (notional) The Health Management Tools within ALIS will display: Fatigue status of the airframe Corrosion status of the airframe Specified Control Points only Sensor

44 SPHM Health Management Screens (notional) The Health Management Tools within ALIS will display: Fatigue status of the airframe Corrosion status of the airframe Specified Control Points only Sensor locations only Control Point Summary Structural usage metrics Individual Aircraft Tracking Actual vs. Baseline Usage High Usage Anomaly Reports Comparisons Time to Inspection metrics Dedicated Screens Remaining Life Estimates Automatic & interactive capability DISTRIBUTION DISTRIBUTION STATEMENT STATEMENT A: Approved A: Approved for Public for Public Release: Release: Distribution Distribution Unlimited is Unlimited 44

45 CTOL Screen Examples (notional) 45

46 Control Point Display Screen (Example) DETAILS CONTROL POINT TRACKING INFORMATION FOR ALL AIRCRAFT EFH/AFH Ratios Variant CTOL Control Point XX Description LH Wing, Rear Spar Attach Initial Flaw Size (in) 0.05 Critical Flaw Size (in) 1.37 Projected End of Life or maintenance Several projections can be produced & End Point can be selected Actual & Baseline DI to compare severity Projected Inspection Points UAI Flight Hours (AFH) Current Flaw Size (in) Equivalent Flight Hours (EFH) EFH/AFH Projected EFH at AFH=8000 Projected AFH at EFH=8000 Remaining AFH to EFH=8000 Previous Maintenance Baseline Inspection Point Projected Inspection Point Flt Hours Date Flaw Size Flaw Size Flt Hours Date Flaw Size (AFH) Date xx N/A N/A Sep Jul-41 xz N/A N/A Jun May-32 xx N/A N/A Mar Jan-40 xx N/A N/A Oct Sep-36 xz N/A N/A Sep Sep-41 Filter A/C Variant & Control Point NOTE : THIS IS A LIVE TABLE AND WILL BE AUTOMATICALLY UPDATED FOLLOWING EACH DATA DOWNLOAD Crack Growth Curve - Control Point XX Flaw Size (inches) Current Flight Hours = 985 Inspection period brought forward to 6750 FH as a result of projected crack length Design predicted critical crack length at 14,600FH - sets initial inspection at 7,300FH Initial Inspection Flaw Size = 0.35in Actual Flaw Size = 0.09in Actual Projected Crack Length (in) Baseline Crack Length (in) FH 6750FH (Intial Inspection) Flight Time (FH) Projections can be changed as a result of inspections and can be based on base/squadron/fleet/country/average usage/high usage/etc Example of a Baseline (based on design/test/updated DADT) & Projected Crack Growth Curve This projection shows that the aircraft is flying with greater severity than design

47 Control Point Summary (Example Only) DISPLAYS A PICTURE OF WHERE THE FLEET/BASE/SQUADRON ARE WITH REGARDS TO SEVERITY OF FLYING CAN BE GENERATED FOR EACH CONTROL POINT This squadron is currently flying (on average) 29% greater severity than design with respect to this control point Control Point Summary Control Point XX Can be projected for different baselines, eg. different bases/squadrons/ countries or DADT Analysis. Equivalent Flight Hours EFH=1.288*AFH EFH=AFH EFH Linear (EFH) Actual Flight Hours 47

48 Individual Aircraft Tracking (Example Only) Aircraft Tail No. SIMILAR INFORMATION TO CONTROL POINT SUMMARY LISTS DADT SUMMARY FOR ALL CONTROL POINTS FOR INDIVIDUAL AIRCRAFT Variant Entry Into Service Date Sortie Info Summary Flight Hours (AFH) No. of Flts XX001 CTOL Jul Highlight Control Points displaying: - high EFH - Predicted inspections significantly brought forward in time Control Point Summary Control Point No. Initial Flaw Size (in) Critical Flaw Size (in) Baseline Crack Growth Life (FH) Current Flaw Size (in) Flight Hours (AFH) Equivalent Flight Hours (EFH) Projected EFH at AFH=8000 Control Point Description EFH/AFH Previous Maintenance Baseline Inspection Point Projected Inspection Point Remaining Date Flaw Size Flaw Size AFH Date Flaw Size AFH AFH Date 0029 LH Wing, Rear Spar, N/A N/A LH HT Spar 1 I/B, Rib 4 shear joint N/A N/A VT Aft root rib, fairing web attachment N/A N/A RH Wing Leading Edge Upper Flange BL N/A N/A Projected AFH at EFH=8000 Remaining AFH to EFH=8000 Could list all monitored control points or (say) top 20 by EFH or AFH to Inspection ALL DATA FOR IAT CAN BE HYPERLINKED WITH AIRCRAFT USAGE SCREENS, EG. EXCEEDENCE PLOTS, LANDING GEAR USAGE, TIME AT MACH-ALT, CONTROL SURFACE USAGE, ETC. Could filter on: -EFH - Projected EFH - Projected AFH - AFH to Inspection 48

49 STOVL/CV Screen Examples (notional) 49

50 Control Point Summary Screen Example DETAILS CONTROL POINT TRACKING INFORMATION FOR ALL AIRCRAFT Click to ENTER user-definable values for projected inspection point calculation Base China Lake Squadron 54 Control Point XX Description LH Wing, Rear Spar Attach SELECT BASE & SQUADRON AND CONTROL POINT TO ANALYSE UAI Flight Hours (AFH) Current FLE Current FLE Rate (per 1000FH) Design FLE Rate (per 1000FH) FLE Limit Remaining FLE Projected AFH at FLE Limit Remaining AFH to FLE limit Remaining AFH to 8000FH Projected Inspection Point (click to enter detail - default=25 FH/Month) Flt Hours FLE (AFH) Date xx N/A N/A N/A xz N/A N/A N/A xx Mar-21 xx N/A N/A N/A xz N/A N/A N/A Current FLE & FLE Rates should include capability to view graphical comparison between squadrons and bases see Slides xx. Base China Lake Squadron 41 UAI FH/Month (Previous 12 months) FH/Month (Life) All z z xa xz yy Projected FH at FLE Limit (highlight a/c that have projected FH < 8,000FH) Projected Inspection Point Enter FH/month 22.8 Current FH/month usage (click to view detail) Click to view FH histories of squadrons50 DISTRIBUTION STATEMENT A: A: Approved for for Public Release: Distribution is is Unlimited

51 High Fatigue Usage Anomaly Report (Example Only) Base China Lake Squadron 54 Control Point XX Description LH Wing, Rear Spar Attach ENABLES BOTH AUTOMATIC & INTERACTIVE ANALYSIS OF AIRCRAFT DISPLAYING HIGH FATIGUE LIFE EXPENDITURE UAI Flight Hours (AFH) Current FLE Current FLE Rate (per 1000FH) Design FLE Rate (per 1000FH) FLE Limit Remaining FLE Projected AFH at FLE Limit Remaining AFH to FLE limit Remaining AFH to 8000FH Projected Inspection Point (click to enter detail - default=25 FH/Month) Flt Hours FLE (AFH) Date xx N/A N/A N/A xz N/A N/A N/A xx Mar-21 xx N/A N/A N/A xz N/A N/A N/A Aircraft displaying severe FLE highlighted RED. AIRCRAFT FATIGUE - ANOMALY REPORT Click to view structural usage history of aircraft UAI Current FLE Rate (per 1000FH) Design FLE Rate (per 1000FH) xx FLE History View FLE History Structural Usage History Sortie Patterns - Mission Utilisation Sortie Patterns - Stores Configuration Sortie Patterns - Flying Hours Landing Gear Usage Load Factor Exceedances Flight Envelope Usage - Mach-Altitude Flight Envelope Usage - Time at Buffet Cockpit Pressurisations Door Openings Speed Brake Usage Control Surface Manoeuvres FLE history can be viewed by clicking and selecting: - UAI - Squadron -Fleet Structural usage history automatically displays RED when usage is significantly more severe than baseline. Detail can be viewed by clicking see next slide. 51

52 High Fatigue Usage Anomaly Report (Example Only) AIRCRAFT FATIGUE - ANOMALY REPORT Current FLE UAI Rate (per 1000FH) Design FLE Rate (per 1000FH) xx View FLE History Structural Usage History Sortie Patterns - Mission Utilisation Sortie Patterns - Stores Configuration Sortie Patterns - Flying Hours Landing Gear Usage Load Factor Exceedances Flight Envelope Usage - Mach-Altitude Flight Envelope Usage - Time at Buffet Cockpit Pressurisations Door Openings Speed Brake Usage Control Surface Manoeuvres ENABLES BOTH AUTOMATIC & INTERACTIVE ANALYSIS OF AIRCRAFT DISPLAYING HIGH FATIGUE LIFE EXPENDITURE FLE FLE History - xx236 (CP XX) FLE Rate/1000FH FH Individual Aircraft FLE History : Highlights any significant changes in the FLE rate FLE FLE vs Flight Hours - Squadron Overview Sqn 54 FLE Rate Sqn 41 FLE Rate Can compare FLE vs. Flight Hours or vs. Landings for different squadrons to provide a comparison. FLE Design FLE Rate Flight Hours Sqn 411 Sqn 54 Linear (Sqn 54) Linear (Sqn 411) 52

53 Predicted Maintenance Screen (Example Only) Predicted DETAILS CONTROL POINTS ON AN INDIVIDUAL Maintenance AIRCRAFT BASIS AND PROJECTED MAINTENANCE point is calculated DATES automatically Filter by Aircraft Tail Number based on the flaw size projections Aircraft Tail Entry Into however No. Variant Service Date Sortie Info Summary capability should Flight Hours exist for manual No. of Flts (AFH) entry as a result XX001 CTOL Jul of in-service arisings. Control Point Summary Control Point No. Control Point Description Previous Maintenance Predicted Maintenance Remaining Date Flaw Size AFH AFH Date 0029 LH Wing, Rear Spar, N/A N/A Nov LH HT Spar 1 I/B, Rib 4 shear joint N/A N/A Jul VT Aft root rib, fairing web attachment N/A N/A Sep RH Wing Leading Edge Upper Flange BL175 N/A N/A Feb-40 Again, could be either: - all monitored control points - top 20 (for example) - control points due for inspection in next 1/3/6/12 month period Remaining Flight Hours to Maintenance shown could list in descending order or highlight those with less than 100 / 50 hours remaining 53

54 Actual vs. Baseline Comparison Data Example CTOL Mission Utilisation - Actual vs. Design Comparison Mission Utilisation (%) ACM BFM ACT GUN TI RAS BSA BSA CAS SAT SAT DI Mission Type Actual / Design Comparison (%) Design Mission Utilisation (%) Actual Mission Utilisation (%) 160 Actual / Design (%) FS Landings Conventional T/Os Touch & Go's Gear Extensions (In-Flight) Gear Extensions (Gnd) Eve nt 54

Flight recreation visualization aids understanding of damaging

55 Structural Event Monitoring Maintainer interface will specify exact tasks to be accomplished to verify structural integrity Flight recreation visualization aids understanding of damaging maneuvers Parameter recording and display available for engineering analysis 55

56 Force Life Management Capability 56

57 Corrosion Model Concept 57

58 Off Board Tools Assess Material Condition Anomaly and Failure Resolution System Knowledge Discovery Force Life Management 58

59 Future Technologies Crack detection and monitoring CVM, MWM technologies Structural Integrity Prognosis System (SIPS) Airframe Reliability and Risk Assessment 59

60 IPT Interaction Aero S/W Struct FTI MS VS GTI SPHM Manuf MSPHM OBPHM Integrity R&M Maint VSPHM AVPHM PHAM u/cphm 60

61 Questions?

F-22 System Program Office

F-22 System Program Office System Program Office Force Management; Overcoming Challenges to Maintain a Robust Usage Tracking Program Wirt Garcia, Robert Bair Program Pete Caruso, Wayne Black, Lockheed Martin Aeronautics Company