Monitoring actual aircraft structural usage could increase rotorcraft safety enhancements provided by Health and Usage Monitoring Systems (HUMS) and could potentially reduce operating costs via usage-based maintenance (UBM) credits. While flight regime recognition (RR) algorithms have been demonstrated, none have been fully validated; additionally, obtaining UBM credit approval remains elusive and presents complex certification issues. The FAA funded this research and development effort to establish and demonstrate a viable approach for validating and certifying HUMS RR-enabled UBM credits. An end-to-end UBM process was defined that fulfills the objectives of Advisory Circular (AC) 29-2C, is technically sound, and works with available HUMS. The Sikorsky Aircraft Corporation (SAC) S-92 aircraft was used as a representative platform to demonstrate elements of the process. The existing S-92 HUMS RR algorithms were evaluated using extensive fleet data. The onboard RR results cannot be used directly because of inconsistencies found with the established SAC fatigue substantiation procedures. However, the onboard algorithms produced sufficiently accurate results to be used for UBM with appropriately defined offboard data mining processing by the rotorcraft original equipment manufacturer. This would allow UBM credit validation and AC compliance without changing the current HUMS installation, onboard RR algorithms, or fatigue substantiation methods. A new postprocessing technique, known as a regime-clustering algorithm, was developed that would be key to successfully mapping HUMS onboard system RR sequence output into selected damaging composite worst-case (CWC) usage spectrum regimes, which can be used in the existing retirement time analytical process. A key feature of the procedure is the automatic calculation of reliability factors that account for uncertainties in the clustering algorithm to maintain the baseline reliability of the original retirement time analytical process. Clustering algorithms were applied to a significant amount of fleet data for a subfleet of ten aircraft. Retirement time adjustments for the S-92 main rotor stationary swash plate were estimated by serial number for individual aircraft and by part number for the subfleet. For an individual component, improvements over the conservative retirement times were approximately 30%-40% based on an assumption of original CWC usage for all future operations. For a fleetwide adjustment, an improvement of more than 100% was shown to be feasible by using an updated CWC usage spectrum throughout the entire component lifetime based on availability of a statistically significant amount of fleet data and implementation of an additional usage monitor reliability factor.


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    Titel :

    Structural Usage Monitoring and Flight Regime Recognition - Compliance Validation and Demonstration Using the Health and Usage Monitoring System Advisory Circular 29-2C MG 15


    Beteiligte:
    P. Bates (Autor:in) / M. Davis (Autor:in) / P. Sadegh (Autor:in)

    Erscheinungsdatum :

    2012


    Format / Umfang :

    213 pages


    Medientyp :

    Report


    Format :

    Keine Angabe


    Sprache :

    Englisch




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