Although HUMS (Health and Usage Monitoring Systems) technology has matured during the last decade, to date CBM has not yet been implemented on a large scale. This paper presents the approach of fatigue management of components and the motivation behind individually adapting the service life of a component to the true load spectrum, which is commonly referred to as Usage Based Maintenance (UBM). Since the actual mission profile is generally expected to be far less severe than the worst case profile, there is a potential to reduce operating costs, to increase operational availability and to reduce the maintenance burden. The paper proposes the UBM End-to-End process starting from Usage data acquisition until UBM credit application in terms of service life limit adjustment. New elements in the process and especially all possible sources of uncertainty will be discussed with focus on the prediction of the Remaining Useful Life (RUL) and the Regime Recognition (RR) system. Furthermore, the paper presents a novel hybrid RR system built up of three stages, which has been developed and validated on three different rotorcraft types. Finally, the RR system reliability is demonstrated on EC 135 flight load survey data and flight test data based from a flight test campaign performed in 2009. The following conclusions can be drawn: (1) A UBM End-to-End process including all major steps, starting from Usage data acquisition until UBM credit application in terms of service life limit adjustment is proposed. (2) As main sources of uncertainty, the prediction of Remaining Useful Life and the Regime Recognition were identified. (3) The principle of individual service life calculation is presented and possible solutions for RUL prediction are described. (4) A novel hybrid and multi-stage regime recognition algorithm system is explained in detail. (5) The Eurocopter Regime Recognition system was validated on a flight load survey database showing average output reliability above 99% when taking the MP mission profile into account. (6) Furthermore the RR system was validated during a flight test campaign against 50 different regimes and several h/c configurations showing superior performance.
Usage based maintenance for dynamic components of rotorcrafts
Betriebszeitbasierte Instandhaltung für dynamische Komponenten von Hubschraubern
2011
9 Seiten, 12 Bilder, 5 Tabellen, 11 Quellen
Aufsatz (Konferenz)
Englisch
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