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Les besoins en maintenance chez EUROCOPTER : les principaux
axes d’amélioration de la maintenance des hélicoptères
Helicopter Maintenance
Research in maintenance
Availability and cost modelling
Reliable Design
Maintenance credit
New Health monitoring solution
Innovative Diagnostic
RFID Logistic mean
Maintenance objectives
Cost• Decrease the maintenance costs • Make the maintenance work easier
Safety• Increase Safety with maintenance low cost actions
Availability• Increase the aircraft availability
Business• Improve the EC business in terms of Maintenance
& Service• Propose a meaningful service/product combination
helicopter maintenance specificities
Airplane Helicopter
Wild body véhicule compact
Equipments all over the AC Centralized equipments
Same product for each AC Personnalised and adaptable HC
Airplane Helicopter
Long range Take off and landing = stress
One mission type A lot of different mission
High altitude Less than 5000m
helicopter maintenance specificities
Airplane Helicopter
Low vibration stress Hight mechanical stress
Specific customer Diversity of customer
Availability as priority Failure localisation to avoid no failure fond
The airplane and the helicopter are two vehicules using the samemaintenance mode but in different objectives and different stress.
helicopter maintenance specificities
The group
Helicopter Maintenance
Research in maintenance
Availability and cost modelling
Reliable Design
Maintenance credit
New Health monitoring solution
Innovative Diagnostic
RFID Logistic mean
Maintenance Research major axis
II - Reliable Design
III - Maintenance credit
V - Innovative Diagnostic
Sensors• Intelligent sensors, able to monitor and send back their state
Sensor
LRULRU
Failures localisation Tools, on ground
Sensors Equipments/ System
Tools Documentation
Trouble shooting
New developments• Integration of testability all along design phases•Suppression of testability demonstration
Trouble shooting• RTG Troubleshooting
Interface Failures• Test words emission on interfaces
Computer
Diagnostic table•Evolution of diagnostic table, Adaptability to helicopter's options• Display of the results in order to ease comprehension of maintenance operations
Old/new avionics Interfaces
• How to test COTS and old avionics interfaces
VI - RFID Logistic mean
I - Availability and cost modelling
IV - New Health monitoring solution
The group
Helicopter Maintenance
Research in maintenance
Availability and cost modelling
Reliable Design
Maintenance credit
New Health monitoring solution
Innovative Diagnostic
RFID Logistic mean
Periodic inspectionNon scheduled maintenanceTrouble shooting
Failure
NTI 1 Inspection / Servicing
PilotFlight engineer
WorkshopPlanning
Base(NTI 2)
Flight engineers
Pilots
CertifiedStation
NTI 1/2/3A
/C to
Ove
rhau
l
Equipment to Overhaul
EnginesManufacturer
Flight Planning
Scenario modeling
Total time= Time required=
8760 h
Effective time of availability
7008 h=80%
Effective time of unavailability
Predictivemaintenance
period
Unavailability time for corrective maintenance
1577 h = 18% €/FH
631 h = 40%
946 h = 60%
Unavailability due to externalreason
Spares supplyingperiod
Failure research & diagnosis period
Reparing period
473 h = 50%
Systematic maintenance period
Additional maintenance period
Active time of corrective
maintenance
Maintenance implementation
period
473 h = 50%
95 h = 15%
536 h = 85%
Flying time
Waiting time
Servicing
Effective waiting time
500 h = 6%
6508 h = 94%
180 h = 2%
Availability modeling
Distribution of the life cycle costs
Reliability
Production costs
Eco-design
Performances
Hardlyreducible
Maintainability
Acquisition25%
Insurance15%Direct
MaintenanceCost
35%
Internal Maintenance
Indirect Maintenance
Withdrawal
Utilization10%
1500€/h
The group
Helicopter Maintenance
Research in maintenance
Availability and cost modelling
Reliable Design
Maintenance credit
New Health monitoring solution
Innovative Diagnostic
RFID Logistic mean
Reliability optimization
Reliability
Product
Environment
Process
The approach« Control of the avionic environment »
Selection of the mostprofitable systems
Prediction of the future H/C DMC Data base of
DMC adjusted
Prevision of the constraintsprofitable to control
Constraints to reduce
Design of the reducingconstraints systems
QuantifiedSystems
Technico-économicalevaluation of the systems
Profitability of the systems
Which constraints to control ?Where controling them ?
2
3
K
6$/hCalculator AP
…
5$/hVisual MFD
DMC observed
2
1,5
∏accpredicted
3€/h
4 ,5€/h
DMC predicted
Instrument panel
Nose
Location in The H/C
1,5
1
∏accoptim
4€/h
3€/h
DMC optim
1€/h
1 ,5€/h
SavedDMC
Temperature spectrumin predicted environment
Temperature Spectrum in observed environment
Temperature Spectrum in controled environment
Design to Reliability
Cooling systems service
Selection of the product in the
market
Technical performances
Reliabilityservice
Thermal service
Profit of DMC
Thermal atmosphere
Technical performances
Reliabilityservice
Thermal service
Profit of DMC
Thermal atmosphere
(1)
(2)
(3) (4)
(5)
(6)
Specification Definition
The group
Helicopter Maintenance
Research in maintenance
Availability and cost modelling
Reliable Design
Maintenance credit
New Health monitoring solution
Innovative Diagnostic
RFID Logistic mean
Utilitaires
Avionique
Moteurs
Structure
Trains
maintenance Opérateur
maintenance Architecture
!
•Detection / Localisation•Diagnostic•Troobleshooting•Maintenance tasks
Warning
Data acquisition on board
Ground levelmaintenance
Health monitoring for Maintenance
Health Usage
Maintenance credits
N°
TBO’
Δ
TTF
H
Anticipation de panne Maintenance corrective
Increase the Time Between Overhaul
Maintenance credits
USAGEHEALTH
Flight data
Indicators
HOMPVibrationanalysis
Decision support
Interpretation
Interface
Acquisition
Corrective maintenance
Health & Usage Monitoring System (HUMS)
Maintenance credits
Vehicle Monitoring for Maintenance & Health Management System
USAGEHEALTH
Flight data
Maintenance credits
HOMPStress-StrainAnalysis
Vibrationanalysis
First failure symptoms
Oil Analysis
Before failure
Decision support
Interpretation
Interface
Acquisition
Health-based maintenance planning
CORRELATION
ADHER CESAR
SHM
The group
Helicopter Maintenance
Research in maintenance
Availability and cost modelling
Reliable Design
Maintenance credit
New Health monitoring solution
Innovative Diagnostic
RFID Logistic mean
For avionics
For Structural parts
New health monitoring solution for Pronostic
• integrated sentinel
• Continuous monitoring
• Evaluation of external solicitations
Pronostic for avionic
Contraintes environnementales:- Cycles thermiques- Sollicitation vibratoires- Corrosion chimique- Hygrométrie…
Dégradation élémentaireinduite
Micro-HUMS
weak or defective
population
SRU PronosticImplementation Prototype
BIHM DEGRADATION CALCULATION ALGORITHMS
Micro-HUMS
environment Identification
Calculation of degradation
Sum of the elementary damages
∑=i i
i
CTFnDamage
Eurocopter Structural Monitoring
Propose a new concept for the maintenance and the operational use of the airframe part of the helicopter
Integration of Structure Health Monitoring for :Flight testsMajor incidentRepairing follow-up for difficult access points
To develop a specific tool to exploit diagnosis structure resultsMaintenance tools for composite, metalic failurediagnostic
Structural Health Monitoring - Ultrasonic Sensors.
Materials of the TailUnit Demonstrator
- Glass cloth / epoxy : 0.05 mm- Bronze grid 50g/m²- 1 ply of carbon /epoxy fibre bi directional : 0.22 mm- 3 plies of Carbon /epoxy fibre uni directional : 3 x 0.17 mm- 1 ply of carbon /epoxy fibre bi directional : 0.22 mm- Film of glue epoxy- Sandwich of Nomex honeycomb: 15 mm- 2 plies of hybrid carbon /glass fibre resin epoxy: 0.25 mm- Film TEDLAR
• Ultrasonic imaging of the upper skin
• Ultrasonic imaging of skin and core
• Visualisation of Lamb wave fields
A-Scan of the upper Skin
The group
Helicopter Maintenance
Research in maintenance
Availability and cost modelling
Reliable Design
Maintenance credit
New Health monitoring solution
Innovative Diagnostic
RFID Logistic mean
On board failure management
Problematic links to the aircraft diagnostic“False Failures”: False warningsFailure Localisation Ambiguity (intrinsic)Failure Propagation
All these problematic lead to :false removal (between 30 and 40% of maintenance operations)Longer maintenance timeLost of confidence in the diagnostic toolCustomer is not satisfied
Diagnostic innovation
Ethernet
GSC
Sensor data correlation algorithm
maintenance computer
Correlation with complementary data
FDS
AMC
AFCS
SENSOR 1
VMSDISPLAY
SENSOR nSENSOR 2
Logical and Temporal Correlation of failure messages
Generate a failure algorithm robust to optional and exportable to other helicopters
Integrates
experience
feed-
back
Telemaintenance
The group
Helicopter Maintenance
Research in maintenance
Availability and cost modelling
Reliable Design
Maintenance credit
New Health monitoring solution
Innovative Diagnostic
Logistic mean
AERONEF ENVIRONMENT
BSITAG
(PN / SN )
Maintenance data transfert
LINK WITH INDUSTRIE
FLEET MANAGEMENT
GROUND ENVIRONMENT
Flotte hélicoptères Filiales réseau mondial
Repair centerstockCustomer
Base de
donnéesglobale
DOCUMENTATION
Analyse usage / santé
Planning révision
Gestion de configuration
CONFIGURATION / HEALTH ,
USAGE DATA /WARNING MESSAGES
LOGISTIC ENVIRONMENT
DATA CONCENTRATOR
CO
NF
DA
TA
RFiD for logistic means
RFiD for health monitoring
Concept : Assume the part following with RFId integrated snesorsWirelessOn ground and in flight
Objective : Usage monitoringIn storage : monitoring of hter storage condition associated to the mechanicalcontainersIn usage : Monitor the real usage condition in the HC ⌦ impact on flight planning
HU
MS
HU
MS
HU
MS
HU
MS
Monitoring in storage
Monitoring in flight
Thank you for your attention
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