PMA209 2012 Core Avionics Master Plan - NAVAIR - U.S. Navy

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Core Avionics Master Plan 2012 Appendix A-5E. Component Health Monitoring. The component health monitoring capabilityelement addresses systems that capture indications of the performance and integrity ofmajor dynamic components on the airframe.1. Current capabilities. Health and usage monitoring; Limited sensors.Many Naval Aviation aircraft incorporate some form of health monitoring capability.Most of these systems are unique and are often managed by platform prime vendors.They are primarily used to record operating time against forecasted airframe fatigue life.Some take selected measurements of key component attributes, or record equivalentstrain and stress counts for engineering calculations of structural life usage. Manylegacy platform maintenance schedules are built around operating time instead of actualcomponent health degradation or evidence of potential impending failure. TheIntegrated Mechanical Diagnostic and Health and Usage Monitoring System (IMDHUMS) is used on both rotary and fixed wing aircraft and assists with maintenancecheck flights, warns of potential defects, tracks operational and structural life usage, andrecords exceedances. Some systems track component vibration signatures to comparethem against known healthy or problem signatures. Some are also designed to analyzesignature change trends to alert maintainers to perform integrity inspections. Few ofthese systems offer any capability to analyze performance trends. Major componentinspections and removals are usually conducted based simply upon time of operation,which does can result in removal and replacement of systems with plenty of useful liferemaining, or allowing degraded equipment to fail before removal.The V-22 uses a Condition Based Maintenance (CBM) maintenance, which isdesigned to monitor actual component condition and performance so that removals andreplacements only occur when they are needed (to reduce workload and cost), and toensure degraded systems are removed before failure (to increase readiness andprevent mishaps). Their Comprehensive Automated Maintenance EnvironmentOptimized (CAMEO) system provides an adaptable, government-owned, open-source(no licensing costs), non-proprietary, Joint-service, Automated Logistics Environment(ALE) and improved Condition Based Maintenance (CBM+) capability, supportingcontinuous integration and automation of operational, maintenance, and logisticalprocesses and technical data to improve aircraft readiness and reduce sustainmentcosts. It incorporates Interactive Electronic Technical Manual (IETM) publications, hostsan integrated prop-rotor track and balancing system, and enables Built In Test (BIT),engine performance and vibrations trending analysis. This system has several plannedupgrades and will eventually tie in with MFOQA functionalities.2. Advanced Research and Technology Development.Sensor Improvements. (2011) This effort is a Small Business Innovative Research(SBIR) initiative that will evaluate the potential for benefits of incorporating microminiaturewireless sensors into health monitoring systems. Wireless components couldbe more easily and cost-effectively fitted to locations that cannot be connected to therecorder by wires. Other digital and material technology advancements are beingapplied to the aircraft and component health monitoring field. Sensors are detectingsignatures over larger frequency ranges with finer sensitivities. Filters are becomingmore capable at detecting smaller metal or composite traces. Some technology gainsare already being incorporated in unmanned aerial vehicles applications.A-5 Flight Safety 10
Core Avionics Master Plan 2012 Appendix A-53. Funded Enhancements and Potential Pursuits.The Joint Aeronautical Commanders Group (JACG) is a Joint Service, three-starlevel agency that is chartered with leveraging commodity system benefits across theServices. They established the Condition Based Maintenance Advisory Board toanalyze benefits of CBM. The board determined that 9-12% of Class A-E mishapsbetween 2002-2008 could have been avoided with active CBM programs, and haveprojected that 11-12 Class A mishaps could be avoided over the next decade. They alsoconcluded that based upon 2010 flight hours, CBM practices could avoid more than$200M per year in parts replacements and drive a 5-8% increase in readiness.Wireless Maintenance Information Download. (2013) The T-45 Digital Data Set(DDS) is being upgraded to incorporate wireless data download of maintenancediagnostic information, which will enable operations planners and ground crews todecrease aircraft turnaround following syllabus events which will ultimately increase theoverall aircraft readiness level. Wireless digital transmission basically eliminates therequirement for additional ground support equipment and minimizes potential corruptionof data seen during manual transfer. The new system transfers the maintenance data inconjunction with recorded mission audio and video data at a rate of 1 gigabits persecond. Current download of engine life monitoring data can take two maintenancepersonnel up to ninety minutes per aircraft. With an average of 300 sorties per day, therapid wireless download capability produces significant man hours and cost savings.The system also enables higher fidelity data collection by increasing the sampling ratefrom 8 to 32 hz.Improved Component Performance Analysis. (2014) When MFOQA is fielded onHornets and Growlers in 2014 it will enable AMATS enhanced trouble-shooting.Maintainers will be able to play back flights and directly observe primary aircraft flightperformance information, maintenance status panel codes, and physical movement ofcontrol surfaces. They will also be able to get a much better feel for the aircraftenvironment and operating parameters that may have contributed to the anomaly at thetime of the occurrence, such as high angle of attack for the engine intake, high g-loadfor actuators, etc.Structural Prognostics and Health Management. (2015) Joint Strike Fighter (JSF)will field Structural Prognostics and Health Management (PHM) capability in support ofmission sortie generation/readiness objectives. Wirelessly downloaded parameters willinclude fuel state, ammunition state, expendables state, and component healthconditions requiring maintenance in order to minimize turnaround time. Real time,accurate down-link of specific component conditions supports CBM, which willsignificantly enhance readiness by enabling maintainers to move from time-scheduledremovals and inspections to removing items only when required. Removing componentsonly when they have achieved their tolerance limit of safe operations can also returnsignificant cost avoidances by extending the lives of the parts beyond their engineeringestimates, thereby reducing the costs of repairs or replacements. CBM may also resultin reduced requirements for spares inventories or deployed spare support footprints.A-5 Flight Safety 11
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PMA209Endorsement and DistributionP
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Table of ContentsExecutive SummaryE
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Core Avionics Master PlanExecutive
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I. INTRODUCTION.Core Avionics Maste
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Core Avionics Master PlanSECNAVISNT
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PMA209 2012 Core Avionics Master Plan - NAVAIR - U.S. Navy

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