A Generic Telerobotics Architecture for C-5 Industrial Processes
The application of telerobotics to aircraft depot maintenance and remanufacturing is described and a telerobotics architecture for the application is discussed.
telerobotics↗
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Study of advanced rotary combustion engines for commuter aircraft
Performance, weight, size, and maintenance data for advanced rotary aircraft engines suitable for comparative commuter aircraft system evaluation studies of alternate engine candidates are provided. These are turbocharged, turbocompounded, direct injected, stratified charge rotary engines. Hypothetical engines were defined (an RC4-74 at 895 kW and an RC6-87 at 1490 kW) based on the technologies and design approaches used in the highly advanced engine of a study of advanced general aviation rotary engines. The data covers the size range of shaft power from 597 kW (800 hp) to 1865 kW (2500 hp) and is in the form of drawings, tables, curves and written text. These include data on internal geometry and configuration, installation information, turbocharging and turbocompounding arrangements, design features and technologies, engine cooling, fuels, scaling for weight size BSFC and heat rejection for varying horsepower, engine operating and performance data, and TBO and maintenance requirements. The basic combustion system was developed and demonstrated; however the projected power densities and performance efficiencies require increases in engine internal pressures, thermal loading, and rotative speed.
Berkowitz, M.↗
Flight service evaluation of advanced composite ailerons on the L-1011 transport aircraft
Flight service evaluation of composite inboard ailerons on the L-1011 under Contract NAS 1-15069 for a period of five years is discussed. The period from July 1984, when the second yearly inspections were completed, through June 1985 is covered. Four shipsets of graphite/epoxy composite inboard ailerons were installed on L-1011 aircraft for this maintenance evaluation program. These include two Delta aircraft and two TWA aircraft. A fifth shipset of composite ailerons were installed in 1980 on Lockheed's flight test L-1011. This aircraft is now inactive and inspections were therefore not performed this year. No visible damage was observed on any of the composite ailerons, and no maintenance action has occurred on any of the composite parts except for repainting of areas with paint loss. Flight hours on the airline components at the time of inspection ranged from 8787 to 10,804 hours, after approximately 3 years of service.
Stone, R. H.↗
Flight service evaluation of advanced composite ailerons on the L-1011 transport aircraft
Flight service evaluation of composite inboard ailerons on the L-1011 are covered. Four shipsets of graphite/epoxy composite inboard ailerons were installed on L-1011 aircraft for this maintenance evaluation program. These include two Delta aircraft and two TWA aircraft. A fifth shipset of composite ailerons were installed in 1980 on Lockheed's flight test L-1011. A visual inspection was also conducted on these components. No visible damage was observed on any of the composite ailerons, and no maintenance action has occurred on any of the parts except for repainting of areas with paint loss. Flight hours on the airline components at the time of inspection ranged from 2886 to 4190 hours, after approximately 1 year of service.
Stone, R. H.↗
Problems with aging wiring in Naval aircraft
The Navy is experiencing a severe aircraft electrical wiring maintenance problem as a result of the extensive use of an aromatic polyimide insulation that is deteriorating at a rate that was unexpected when this wire was initially selected. This problem has significantly affected readiness, reliability, and safety and has greatly increased the cost of ownership of Naval aircraft. Failures in wire harnesses have exhibited arcing and burning that will propagate drastically, to the interruption of many electrical circuits from a fault initiated by the failure of deteriorating wires. There is an urgent need for a capability to schedule aircraft rewiring in an orderly manner with a logically derived determination of which aircraft have aged to the point of absolute necessity. Excessive maintenance was demonstrated to result from the accelerated aging due to the parameters of moisture, temperature, and strain that exist in the Naval Aircraft environment. Laboratory studies have demonstrated that MIL-W-81381 wire insulation when aged at high humidities followed the classical Arrhenius thermal aging relationship. In an extension of the project a multifactor formula was developed that is now capable of predicting life under varying conditions of these service parameters. An automated test system has also been developed to analyze the degree of deterioration that has occurred in wires taken from an aircraft in order to obtain an assessment of remaining life. Since it is both physically and financially impossible to replace the wiring in all the Navy's aircraft at once, this system will permit expedient scheduling so that those aircraft that are most probable to have wiring failure problems can be overhauled first.
Campbell, Frank J.↗
Managing Maintenance Error: Six Lessons From Aviation Maintenance
There are clear parallels between the ground processing of spacecraft and the maintenance of airline aircraft. In both cases, reliable human performance is critical to safe outcomes. Examples of human factors in airline maintenance and spacecraft ground processing illustrate the similarities between these two domains. The worldwide aviation industry began to pay close attention to human factors in maintenance after several maintenance-related disasters in the 1970s and 80s. Rather than simply applying solutions that had been developed for flight crew and air traffic controllers, the aviation industry developed human factors interventions specifically tailored for maintenance personnel. These interventions have led to safety improvements, greater reliability, and significant cost savings. Six human factors approaches from airline maintenance that can be usefully applied to enhance the quality and safety of ground processing are outlined. These are 1) Design for assembly, test, and maintenance, 2) Non technical skills training, 3) Improved design of documentation, 4) Reduction of iatrogenic quality lapses, 5) Barrier and control analysis, and 6) Continuous improvement based on learning from quality lapses.
maintenance human factors↗
Feasibility Study of a Rotorcraft Health and Usage Monitoring System (HUMS): Results of Operator's Evaluation
The objective was to evaluate the feasibility of a state-of-the-art health and usage monitoring system (HUMS) to provide monitoring of critical mechanical systems on the helicopter, including motors, drive train, engines, and life-limited components. The implementation of HUMS and cost integration with current maintenance procedures was assessed from the operator's viewpoint in order to achieve expected benefits from these systems, such as enhanced safety, reduced maintenance cost, and increased availability. An operational HUMS that was installed and operated under an independent flight trial program was used as a basis for this study. The HUMS equipment and software were commercially available. Based on the results of the feasibility study, the HUMS used in the flight trial program generally demonstrated a high level of reliability in monitoring the rotor system, engines, drive train, and life-limited components. The system acted as a sentinel to warn of impending failures. A worn tail rotor pitch bearing was detected by HUMS, which had the capability for self testing to diagnose system and sensor faults. Examples of potential payback to the operator with HUMS were identified, including reduced insurance cost through enhanced safety, lower operating costs derived from maintenance credits, increased aircraft availability, and improved operating efficiency. The interfacing of HUMS with current operational procedures was assessed to require only minimal revisions to the operator's maintenance manuals. Finally the success in realizing the potential benefits from HUMS technology was found to depend on the operator, helicopter manufacturer, regulator (FAA), and HUMS supplier working together.
Romero, Raylund↗
Application and Certification of Comparative Vacuum Monitoring Sensors for Structural Health Monitoring of 737 Wing Box Fittings
Multi-site fatigue damage, hidden cracks in hard-to-reach locations, disbonded joints, erosion, impact, and corrosion are among the major flaws encountered in today's extensive fleet of aging aircraft and space vehicles. The use of in-situ sensors for real-time health monitoring of aircraft structures are a viable option to overcome inspection impediments stemming from accessibility limitations, complex geometries, and the location and depth of hidden damage. Reliable, structural health monitoring systems can automatically process data, assess structural condition, and signal the need for human intervention. Prevention of unexpected flaw growth and structural failure can be improved if on-board health monitoring systems are used to continuously assess structural integrity. Such systems are able to detect incipient damage before catastrophic failures occurs. Condition-based maintenance practices could be substituted for the current time-based maintenance approach. Other advantages of on-board distributed sensor systems are that they can eliminate costly, and potentially damaging, disassembly, improve sensitivity by producing optimum placement of sensors and decrease maintenance costs by eliminating more time- consuming manual inspections. This report presents a Sandia Labs-aviation industry effort to move SHM into routine use for aircraft maintenance. This program addressed formal SHM technology validation and certification issues so that the full spectrum of concerns, including design, deployment, performance and certification were appropriately considered. The Airworthiness Assurance NDI Validation Center (AANC) at Sandia Labs, in conjunction with Boeing, Delta Air Lines, Structural Monitoring Systems Ltd., Anodyne Electronics Manufacturing Corp. and the Federal Aviation Administration (FAA) carried out a certification program to formally introduce Comparative Vacuum Monitoring (CVM) as a structural health monitoring solution to a specific aircraft wing box application. Validation tasks were designed to address the SHM equipment, the health monitoring task, the resolution required, the sensor interrogation procedures, the conditions under which the monitoring will occur, the potential inspector population, adoption of CVM into an airline maintenance program and the document revisions necessary to allow for routine use of CVM as an alternate means of performing periodic structural inspects. To carry out the validation process, knowledge of aircraft maintenance practices was coupled with an unbiased, independent evaluation. Sandia Labs designed, implemented, and analyzed the results from a focused and statistically-relevant experimental effort to quantify the reliability of the CVM system applied to the Boeing 737 Wing Box fitting application. All factors that affect SHM sensitivity were included in this program: flaw size, shape, orientation and location relative to the sensors, as well as operational and environmental variables. Statistical methods were applied to performance data to derive Probability of Detection (POD) values for CVM sensors in a manner that agrees with current nondestructive inspection (NDI) validation requirements and also is acceptable to both the aviation industry and regulatory bodies. This report presents the use of several different statistical methods, some of them adapted from NDI performance assessments and some proposed to address the unique nature of damage detection via SHM systems, and discusses how they can converge to produce a confident quantification of SHM performance An important element in developing SHM validation processes is a clear understanding of the regulatory measures needed to adopt SHM solutions along with the knowledge of the structural and maintenance characteristics that may impact the operational performance of an SHM system. This report describes the major elements of an SHM validation approach and differentiates the SHM elements from those found in NDI validation. The activities conducted in this program demonstrated the feasibility of routine SHM usage in general and CVM in particular for the application selected. They also helped establish an optimum OEM-airline-regulator process and determined how to safely adopt SHM solutions. This formal SHM validation will allow aircraft manufacturers and airlines to confidently make informed decisions about the proper utilization of CVM technology. It will also streamline the regulatory actions and formal certification measures needed to assure the safe application of SHM solutions.
42 ENGINEERING↗
A generic telerobotics architecture for C-5 industrial processes
The feasibility of applying telerobotics to the maintenance of C-5A aircraft is discussed. A variety of maintenance applications are evaluated for the inclusion of telerobotics technology.
Backes, Paul G.↗
Analysis of the GOES 6.7 micrometer channel observations during FIRE 2
Clouds form in moist environments. FIRE Phase II Cirrus Implementation Plan (August, 1990) noted the need for mesoscale measurements of upper tropospheric water vapor content. These measurements are needed for initializing and verifying numerical weather prediction models and for describing the environment in which cirrus clouds develop and dissipate. Various instruments where deployed to measure the water vapor amounts of the upper troposphere during FIRE II (e.g. Raman lidar, CLASS sonds and new cryogenic frost hygrometer on-board aircraft). The formation, maintenance and dissipation of cirrus clouds involve the time variation of the water budget of the upper troposphere. The GOES 6.7 mu m radiance observations are sensitive to the upper tropospheric relative humidity, and therefore proved extremely valuable in planning aircraft missions during the field phase of FIRE II. Warm 6.7 mu m equivalent black body temperatures indicate a relatively dry upper troposphere and were associated with regions generally free of cirrus clouds. Regions that were colder, implying more moisture was available may or may not have had cirrus clouds present. Animation of a time sequence of 6.7 mu m images was particularly useful in planning various FIRE missions. The 6.7 mu m observations can also be very valuable in the verification of model simulations and describing the upper tropospheric synoptic conditions. A quantitative analysis of the 6.7 mu m measurement is required to successfully incorporate these satellite observations into describing the upper tropospheric water vapor budget. Recently, Soden and Bretherton (1993) have proposed a method of deriving an upper tropospheric humidity based on observations from the GOES 6.7 mu m observations. The method is summarized in the next section. In their paper they compare their retrieval method to radiance simulations. Observations were also compared to ECMWF model output to assess the model performance. The FIRE experiment provides a unique opportunity to further verify the GOES upper tropospheric relative humidity retrieval scheme by providing (1) aircraft observations to cross-validate the calibration of the GOES 6.7 mu m channel, (2) accurate upper tropospheric water vapor concentrations for verification, and (3) veritical variability of upper tropospheric water vapor.
Soden, B. J.↗
Data Mining for Anomaly Detection
The Vehicle Integrated Prognostics Reasoner (VIPR) program describes methods for enhanced diagnostics as well as a prognostic extension to current state of art Aircraft Diagnostic and Maintenance System (ADMS). VIPR introduced a new anomaly detection function for discovering previously undetected and undocumented situations, where there are clear deviations from nominal behavior. Once a baseline (nominal model of operations) is established, the detection and analysis is split between on-aircraft outlier generation and off-aircraft expert analysis to characterize and classify events that may not have been anticipated by individual system providers. Offline expert analysis is supported by data curation and data mining algorithms that can be applied in the contexts of supervised learning methods and unsupervised learning. In this report, we discuss efficient methods to implement the Kolmogorov complexity measure using compression algorithms, and run a systematic empirical analysis to determine the best compression measure. Our experiments established that the combination of the DZIP compression algorithm and CiDM distance measure provides the best results for capturing relevant properties of time series data encountered in aircraft operations. This combination was used as the basis for developing an unsupervised learning algorithm to define "nominal" flight segments using historical flight segments.
Biswas, Gautam↗
An artificial intelligence-based structural health monitoring system for aging aircraft
To reduce operating expenses, airlines are now using the existing fleets of commercial aircraft well beyond their originally anticipated service lives. The repair and maintenance of these 'aging aircraft' has therefore become a critical safety issue, both to the airlines and the Federal Aviation Administration. This paper presents the results of an innovative research program to develop a structural monitoring system that will be used to evaluate the integrity of in-service aerospace structural components. Currently in the final phase of its development, this monitoring system will indicate when repair or maintenance of a damaged structural component is necessary.
Grady, Joseph E.↗
Detection of structural deterioration and associated airline maintenance problems
Airline operations involving the detection of structural deterioration and associated maintenance problems are discussed. The standard approach to the maintenance and inspection of aircraft components and systems is described. The frequency of inspections and the application of preventive maintenance practices are examined. The types of failure which airline transport aircraft encounter and the steps taken to prevent catastrophic failure are reported.
Henniker, H. D.↗
STOL propulsion systems
The selection and the characteristics of quiet, clean propulsion systems for STOL aircraft are discussed. Engines are evaluated for augmentor wing and externally blown flap STOL aircraft with the engines located both under and over the wings. Some supporting test data are presented. Optimum engines are selected based on achieving the performance, economic, acoustic, and pollution goals presently being considered for future STOL aircraft. The data and results presented were obtained from a number of contracted studies and some supporting NASA inhouse programs, most of which began in early 1972. The contracts include: (1) two aircraft and mission studies, (2) two propulsion system studies, (3) the experimental and analytic work on the augmentor wing, and (4) the experimental programs on Q-Fan. Engines are selected and discussed based on aircraft economics using the direct operating cost as the primary criterion. This cost includes the cost of the crew, fuel, aircraft, and engine maintenance and depreciation.
Denington, R. J.↗
Aircraft wiring program status report
In this Naval Air Warfare Center (NAWC) Aircraft Division status report, the general and wire and cable component activities, the systems engineering activities, the aircraft wiring lead maintenance activities, the NAVAIR/NASA interface activities, and the Base Realignment and Closure (BRAC) Commission recommendations are presented.
Beach, Rex↗
Surface Enhancement Improves Crack Resistance
The low plasticity burnishing (LPB) process produces a deep layer of surface compression in a quick and affordable manner to produce metal surfaces free of scratches, nicks, and gouges. The process, designed for easy inclusion in the manufacturing environment, can be performed with conventional Computer Numerical Control machine tools. This allows parts to be processed during manufacturing, rather than as a post process in a separate facility. A smooth, free-rolling spherical ball suspended in a fluid allows for single-point contact. The ball comes into mechanical contact only with the surface to be burnished, and can be moved in any direction. LPB can be applied to all types of carbon and alloy steel, stainless steel, cast iron, aluminum, titanium, and nickel- based super alloys. In addition to improving a surface's resistance to fatigue and damage, treatment stops the growth of shallow cracks. The LPB process is used on the leading edges of turbine blades to improve resistance to foreign object damage and crack growth. This means significant savings for aircraft owners, since maintenance requirements to inspect for fatigue damage, replace parts, and remove corrosion damage increase the cost of operation.
Source record↗
In-Situ Wire Damage Detection System
An In-Situ Wire Damage Detection System (ISWDDS) has been developed that is capable of detecting damage to a wire insulation, or a wire conductor, or to both. The system will allow for realtime, continuous monitoring of wiring health/integrity and reduce the number of false negatives and false positives while being smaller, lighter in weight, and more robust than current systems. The technology allows for improved safety and significant reduction in maintenance hours for aircraft, space vehicles, satellites, and other critical high-performance wiring systems for industries such as energy production and mining. The integrated ISWDDS is comprised of two main components: (1) a wire with an innermost core conductor, an inner insulation film, a conductive layer or inherently conductive polymer (ICP) covering the inner insulation film, an outermost insulation jacket; and (2) smart connectors and electronics capable of producing and detecting electronic signals, and a central processing unit (CPU) for data collection and analysis. The wire is constructed by applying the inner insulation films to the conductor, followed by the outer insulation jacket. The conductive layer or ICP is on the outer surface of the inner insulation film. One or more wires are connected to the CPU using the smart connectors, and up to 64 wires can be monitored in real-time. The ISWDDS uses time domain reflectometry for damage detection. A fast-risetime pulse is injected into either the core conductor or conductive layer and referenced against the other conductor, producing transmission line behavior. If either conductor is damaged, then the signal is reflected. By knowing the speed of propagation of the pulse, and the time it takes to reflect, one can calculate the distance to and location of the damage.
Williams, Martha↗
The Second Joint NASA/FAA/DoD Conference on Aging Aircraft
The purpose of the Conference was to bring together world leaders in aviation safety research, aircraft design and manufacturing, fleet operation and aviation maintenance to disseminate information on current practices and advanced technologies that will assure the continued airworthiness of the aging aircraft in the military and commercial fleets. The Conference included reviews of current industry practices, assessments of future technology requirements, and status of aviation safety research. The Conference provided an opportunity for interactions among the key personnel in the research and technology development community, the original equipment manufacturers, commercial airline operators, military fleet operators, aviation maintenance, and aircraft certification and regulatory authorities. Conference participation was unrestricted and open to the international aviation community. Appendix B contains the name and addresses of the 623 participants in the Conference.
Harris, Charles E.↗