maintenance research EC - lis-lab.fr research EC.pdf · Visual MFD 5$/h DMC observed 2 1,5 ∏acc predicted 3€/h 4 ,5€/h DMC predicted Instrument panel Nose Location in The H/C

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


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.


The group




Reliable Design

Maintenance credit



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




Reliable Design

Maintenance credit



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




Reliable Design

Maintenance credit



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




Reliable Design

Maintenance credit



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




Reliable Design

Maintenance credit



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




Reliable Design

Maintenance credit



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




Reliable Design

Maintenance credit



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

Documents

maintenance research EC - lis-lab.fr research EC.pdf · Visual MFD 5$/h DMC observed 2 1,5 ∏acc predicted 3€/h 4 ,5€/h DMC predicted Instrument panel Nose Location in The H/C