Technology Today issue 1 2008 - Raytheon

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Special Interest Continued from page 35 There are three levels of PHM concurrently being developed by Raytheon: Embedded prognostic technologies Secure net-centric data communication and storage Health management data processing and control War Planner Health Mgmt. Center 5 Low Priority Equipment Orders Placed MISSION READINESS/SUCCESS DATA 3 Mission Success Report FIELD EQUIPMENT ORDERS Logistics 36 2008 ISSUE 1 RAYTHEON TECHNOLOGY TODAY 4 FIELD DATA ANALYSIS Equipment Remaining Useful Life (RUL) Report The Joint Strike Fighter program office defined health management concepts as follows: Classified Network 2 Pre-cursor to Failure Data Reported MISSION ASSURED EQUIPMENT DELIVERY 6 Equipment Delivered Before Next Mission Diagnostics: the process of determining the state of a component to perform its function(s) Prognostics: the predictive diagnostics, which include determining the remaining life or time span of proper operation of a component ENCRYPTED FIELD REPORTS Future Prognostics Scenario Field Support 1 Equipment Pre-cursor to Failure Data Detailed Fielded Equipment 7 Equipment Repaired Before Mission Figure 2. In a future prognostics-based mission support scenario the platform senses incipient failures, (failures in process) and equipment failures, and reports a predictive RUL. This precursor to failure information is automatically collected by the platform and securely networked back to the war planner and health management center without maintainer intervention. Low-priority equipment can then be replaced and shipped to the battlefield using normal logistics capabilities. Since the equipment is delivered before the platform fails and before the next mission, both missions are assured of failure-free operation. (2) Tank Needs Repair in 2 Days Mission Planner Prognostics Health Management Center (PHMC) Coordinator Healthy Mission Computer (3) Deploy to Front (1) MC has 2 Days Remaining Useful Life (4) Pull Back Tomorrow FIELD REPAIR Healthy Mission Computers Sick Mission Computer (6) One Day Egress (5) One Day Ingress Figure 3. The PHM common operational picture provides the integrated capability to receive, correlate and display a complete system status, including planning applications and theatergenerated overlays and projections. Prognostics and Health Management Health management: The capability to make appropriate decisions about maintenance actions based on diagnostic/prognostics information, available resources and operational demand Raytheon recognizes that before mission planners and logisticians can mitigate incipient failures, new innovative precursor technologies and prognostic algorithms must be integrated into both existing and future products, and this involves all phases of product development. These precursor technologies include: Physics of failure (PoF) research Sensor design and signal conditioning development Prognostic reasoner algorithm development Prognostic and Health Management Capabilities Involve All Engineering Disciplines Prognostic development begins by investigating a product’s PoF mechanism for each of the product’s technologies (RF digital, power, mechanical, etc.), over all of the product’s operational environments (vibration, temperature, etc.). The PoF data is then integrated with available experimental field and factory data to create a technology-specific PoF model. Prognostic sensors are then integrated into the product to measure the predictive parameters specified by the PoF models. After integrating the technology PoF models into the overall product PoF model, prognostication algorithms are applied to predict the product’s RUL. If necessary, new sensors are added, or removed, depending on product models. All aspects of the prognostic design are made to be programmable to facilitate prognostic maturation throughout the product’s life cycle. Robust Embedded Test Architecture Raytheon also developed a real-time robust embedded test architecture (RET-A) that standardizes the execution and reporting of embedded diagnostics and prognostics features and provides a standard product to test equipment interfaces. RET-A enables efficient integration of specific PHM technologies and provides the framework to reuse designs that leverage companywide embedded prognostic solutions across multiple products.
PHM Conceptual Overview Prognostics Sensor Design Prognostics Models and Thresholds Analysis Unit Reasoner Remaining Useful Life (RUL) Algorithm Development Sensors Collaboration and Leadership Prognostics – Temp-Time-Vib-Humidity Models Voltage Controls To leverage investments and reduce stovepipe developments, Raytheon established the Mission Support Enterprise Campaign, PHM Steering Committee and PHM Technical Interest Group that together provide a One Raytheon approach to developing PHM solutions internally, as well as with industry, academia and our DoD customers. Assuming a leadership role, Raytheon is also partnering with universities, industry partners, trade associations and small businesses. Innovative solutions learned from these associations are also being integrated into Raytheon products. Disruptive Technology PHM is a disruptive technology that is dramatically changing how Raytheon develops, tests, manufactures and deploys products. New engineering processes and tools are being developed for each engineering discipline to enable PHM techniques to be developed and reused across Raytheon independent research and development programs. tb t1 t2 Time Physics of Failure (PoF) Analysis for Product Environment is used to define Reasoner Algorithm Sensor Conditioners One of the cornerstones that make Raytheon a world-class engineering company is the adherence to, and evolution of, the Raytheon Integrated Product Development System. Tp1 Robust Embedded Test Ref Arch Special Interest Engineering Physics of Failure (PoF) Analysis PoF Models and Thresholds RUL Models and Reasoner Controls Reasoner Remaining Useful Life Reasoner Design Engineering Development Design and Analysis Data Embedded Solutions RUL Remaining Useful Life Figure 4. A deployed PHM standard will improve our competitive postion. PHM Systems and Software Architecture Design Remaining Useful Life Prediction As a disruptive technology, PHM is being deployed throughout all phases of product development, including: Internal research and development Mission Assurance and Mission Support architectures and applications System architectures Product architectures Design and development Production testing Field testing Warranty contracts The development and integration of prognostics and health management technologies will provide NoDoubt Mission Assurance for the warfighters who depend on Raytheon’s systems to work the first time, and every time. In addition, it is an area of development that will provide a competitive advantage that will differentiate Raytheon from other companies in our markets. John P. Bergeron john_ p_ bergeron@raytheon.com Contributor: Brad Schupp ENGINEERING PROFILE John P. Bergeron Director, Whole Life Engineering Raytheon Integrated Defense Systems After spending the first six years of his career in design and engineering, John Bergeron went to the field for installation and operation of one of the products he worked on. That’s when he discovered his enjoyment of the hands-on aspect of engineering from the end-user’s perspective. From then on, his career focused on after-shipment services and long-term sustainment. “Following a product that I designed to the field made a big difference to me,” Bergeron said. “I encourage all engineers to spend some time in the field. It gives you a different perspective. You see how your design changes affect the customer when they are looking over your shoulder and asking, ‘does it work yet?’” One of the biggest challenges of Bergeron’s job is ensuring that the design engineers understand the importance of product serviceability for the life of the product. It helps, Bergeron said, that “the technology Raytheon delivers is excellent, and I work with really smart people.” Still, he added, “I think we could do a better job leveraging long-term service contracts for our products by designing the ‘hooks and handles’ in them.” Bergeron believes that an important thing to remember about working with others is, “Everyone deserves honest and candid feedback,” he said. “The best performance review I ever received was also the toughest, but I appreciated it.” Reflecting on what about his job excites him, he said, “The endless opportunities. I just wish we could do more, faster.” And what keeps him up at night? “What I don’t know — and my 18-month-old daughter.” RAYTHEON TECHNOLOGY TODAY 2008 ISSUE 1 37
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