SBIR-STTR Award

The objective of this project is to develop and validate improved methodology for the substantiation and the usage-based tracking of rotorcraft dynamic system components. A Helicopter Information Retrieval & Substantiation System(HIRSS) is proposed which consists of (1) an Universal Damage Tracking Algorithm(TM) capable of accommodating the different fatigue analysis methodologies of the manufacturers, (2) a flight loads and logistics database management system, and (3) a CAD-based scenario modeler which allows damage summation scenarios to be constructed using point n'click modeling. With the flight loads DBMS, a scalable flight loads database that can be queried by the damage summation algorithm can be automatically built from flight data tapes. With the logistics DBMS, the HIRSS can serve as a base station for processing data from on-board HUMS, and as a maintenance and logistics decision support system. With the scenario modeler, the HIRSS can serve as a methodology development platform, whereby nested multi-level Monte Carlo risk assessments can be set-up or modified, using point n'click modeling, to assess the role of each stochastic driver on the reliability of a member. Availability of the HIRSS can lead to an improved substantiation methodology for dynamic system components. It can help identify any conservatisms which may lead to the premature or unnecessary removal of components, leading to lower operating costs to fleet operators. Because the HIRSS also allows certifying agencies to independently corroborate retirement times, it can also "force" the development of an universal substantiation methodology for the rotorcraft industry.

Keywords:
Fatigue, Risk Assessment, Monte Carlo, Aging Aircraft, Damage Tolerance, Hums, Reliability

The objective of the Phase II research is to utilize the lessons learned from the Phase I risk reduction work to develop a prototype CAD-programmable environment for the development of condition-based maintenance systems for rotorcraft. This development environment features a CAD scenario modeler for constructing, via click n' drag modeling, fault-to-failure damage models which can account for the effects of usage, as well as anomalous or faulted conditions, on the remaining useful life of mechanical systems. Key features of the software system are: 1. Quantifies structural reliability on an absolute basis using advanced probabilistic methodology. 2. Compatible with the vagaries of each manufacturer's methodology to facilitate industry wide acceptance. 3. Multi-modal operation as (a) damage computation kernel for HUMS base station, (b) research tool for the development of fault-to-failure damage models for predictive diagnostics systems, (c) CAD-based programming environment for development of predictive diagnostics algorithms for embedded prognostics systems, and (d) run-time kernel for embedded prognostics systems. The availability of this tool will facilitate the development of rotorcraft condition-based maintenance systems with the predictive diagnostics capabilities to determine the remaining useful life when anomalies or faulted conditions are encountered. Approach promises significant reductions in life cycle costs by eliminating unnecessary equipment retirement at a preset life, while also protecting against premature failures due to anomalous or faulted conditions. The approach also promises significant increases in equipment readiness levels, by detecting and tracking the progression of damage due to anomalous or faulted conditions so that appropriate preventive action can be taken on a timely basis

Keywords:
predictive diagnostics, condition-based maintenance, fatigue, hums, rotorcraft, reliability, cad