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1 Air Force Research Laboratory Defending America by Unleashing the Power of Innovative Aerospace Technology Integrated Systems Health Management The Key to Future Aerospace System Mark M. Derriso ISHM Product Lead, Operationally Responsive Spacelift Air Vehicles Directorate Air Force Research Laboratory I n t e g r i t y - S e r v i c e - E x c e l l e n c e
2 Integrated Systems Health Management Any system that collects, processes and manages health data to assess the current condition of an aerospace vehicle and determine its ability to perform a given mission. Determine Ability to Perform Mission Assess Damage Detect Damage
3 Concept of Operation Assess High Level Reasoning Engine Health Data (Vehicle Subsystems Health Data) Maintenance Depot Act Control Algorithms Adaptive Flight Control System Surface Control Plan Off-board Condition-Based Maintenance On-board Real-Time Replanning Flight Management System Health Assessment Vehicle Capabilities Maintenance Action Mission Planning Flight Planning
4 AFRL/VA Future Warfighter Capabilities
5 ORS Technology Roadmap Goals - Key Need is Aircraft-Like Ops - Numerous Concepts and Designs Available BASELINE EELV, Shuttle, Aircraft U.S. Air Force Phase I Rapid turn 48 hrs Low sortie cost $10M Vehicle reliability All Wx availability 90% 250 Sortie Airframe 100 Sortie Propulsion/Systems Near Term Phase II Rapid turn 24 hrs Low sortie cost $5M Vehicle reliability All Wx availability 95% 500 Sortie Airframe 250 Sortie Propulsion/ Systems Performance Gains Traded for Operability Enhancements Mid Term Phase III Rapid turn 4 hrs Low sortie cost $1M Vehicle reliability All Wx availability 98% 1,000 Sortie Airframe 500 Sortie Propulsion/ Systems Far Term
6 Integrated Systems Health Management Any system that collects, processes and manages health data to to assess the current condition of of a vehicle and determine its its ability to to perform a given mission. Mission Capability Determine Vehicle Health Assessment Decreases: Turn Turn Time, Time, Sortie Sortie Cost Cost Increases: Vehicle Reliability, Vehicle Availability Automatic Vehicle Certification
7 Operationally Responsive Spacelift Product Taxonomy Sub-Capability Rapid Turn/ Low Cost Ops Turn Time (hrs) Sortie Cost ($) Product (Current Spiral) Quick Turn Struct/TPS - Decreased TPS turn time/mmhrs - Increased struc/tps durability RLV Integration Tech - Decreased turn time/mmhrs - Operability optimized designs High Reliability Loss of Vehicle (Prob( Prob) High Weather Availability Wx Cnx (Prob) IVHM for RLVs Full Envelope A-G&C Durable Hot Struct (long lead) - Decreased inspection time - Decreased unscheduled maint - Increased system reliability - Decreased Loss-of-Vehicle chance - Decreased mission planning time - Increased weather envelope - Increased durability - Decreased TPS turn time/mmhrs - Increased weather envelope Risk Quant d Struct Design - Optimized structural margins
8 RLV Integration Technology Sim Based R&D Flight Test Modeling Modeling&&Simulation Simulation Integration IntegrationStudies Studies 6 Demonstrate Demonstrate Turn Time Call Up Time 5 Campaign Maintenance Man-hrs/Sortie Marginal Cost/Sortie Reliability 4 Weather Sensitivity Composite Mission / Engagement Fundamental Sciences 0 HTHL VTHL VTVL Integrate for Operability: Turn Time, Cost, Reliability, Wx Availability EMAs Mechanically Attached TPS Durable TPS < 3000oF Hot Structure Low Manpower Operations Non-Toxic OMS/RCS Highly Operable Main Engines IVHM Integrated Subsystems Adaptive Controls Rapid Mate & Fuel Intelligent Maintenance
9 Operationally Responsive Spacelift Capability (IDEAL) Product: Integrated System Health Management CMUS IPHM SOVOCS 3 ISHM Concept Arch Study (ML) Support 2 Proactive Controls Health Management 2 System Health Capability Reasoner Development ISHM System Design & Impact Assessment HM for Structural Hot Spots 3 3 ISHM Sub-Systems Integration Demo 3 3 Controls System Level System Capability Health Algorithms Reasoner 5 AG&C / HM Integration 4 6.1/SBIR Effort 6.2 Program 6.3 Program Other Funding Leveraged Program Funded Transition Unfunded Transition 5 Technology Readiness Level Transition Point (TAD) Products S1 Spiral ISHM Architecture Design & Simulation Models ISHM Validation Test SOV Structural Health Management (HE) Off-Board HM 3 4 Int. RLV Structures Demo-Fuselage 5 AG&C / HM Validation 5 Integrated System Health Management for SOV (PR) Propulsion HM S1 Structural Health Algorithms(TPS/Tanks) Total Prod Cost ($K)
10 SOV Structural Health Monitoring Technology Investment Schedule SHM Technique Selection Prior Years Algorithms Development SHM Testing POC: Mark M. Derriso, (937) Description AFRL/VA Funding ($M) Benefits to the War Fighter Develop structural health monitoring(shm) techniques that would detect impact damage, bondline integrity, and cracks in airframe structure/tps for future highspeed vehicles, such as the SOV and FSA. Technology High temperature sensors Digital Signal Processing (DSP) Advanced signal analyses Physics-based modeling Reduce O&M cost Maintain flight safety Increase availability Platforms Space Operations Vehicle (SOV) Long Range Strike Vehicle (LRSV)
11 Proactive Controls Health Management (PCHM) IGNC reconfigures control surfaces and propulsion profile to reduce stress on indicted component ISHM monitors control surfaces, collects data and communicates status to mission control Sub-Orbital/Orbital Ascent Actuator fault prognosed ISHM VMS- IGNC interact for reconfiguration or possible mission variation SENSORS Safe Reliable Versatile Available FLIGHT RCS PWR LOADS Reentry/Descent ISHM records data for download and possible maintenance action after successful mission Launch ISHM Landing/Reflight
12 Integrated System Health Management Operationally Responsive Space Access Optical Sensors : Product Development Schedule ISHM Architecture Design System Health Capability Reasoner Actuator Health Management OCPS: EMAs Affordable WDM: Structural Usage Monitoring (temp) Structural Usage Monitoring (load) ISHM Subsystem Integration Demo Description Benefits to the User Development of vehicle-level health management system that collects and process data from subsystems and provides vehicle information to be used pre-flight, in-flight and post-flight. Technology Challenges Characterizing vehicle s degradation and capability in harsh environments. (temp, acoustic, etc.) Interpreting sensor information into vehicle s condition via diagnostics algorithms in near real-time. Integrating, managing and processing sensor data in real-time. Minimal turn-around time is achieved with the diagnostic tools for early identification, accurate assessment and timely maintenance of subsystem degradation during pre-flight and postflight Higher vehicle operation reliability is achieved by updating in-flight the vehicle s guidance and control system with its current capabilities and limitations Lower cost of operation is achieved with the prognostic tools to allow the repair & replace schedule to be integrated with the flight schedule
13 Integrated RLV Structures Demo Requires Flight Test Tank Technology Ready for Scale Up Mechanically Attached Thermal Protection Systems Primary Structure Ready to Apply Tanks Structural IVHM Health Monitoring Requires Incremental Flight Test Integration is Key Risk Area
14 ORS Flight Demo Path Forward - Technology Integration Transition Su Air bs cra ys ft tem s Technology Integration Aircraft-Like Ops Aircraft Like Space Access Airframe TPS op r P on i s ul ORS µ-x ATD st Spiral Technology Transition to Acquisition
15 Operationally Responsive Spacelift Products Availability Forecast U.S. Air Force Products Quick-Turn TPS AG&C - Approach & Landing Products Hot Structures Full Envelope AG&C Integrated RLV Health Management Products Hot Structures (Spiral 2) Integrated AG&C/ Structure/Propulsion/IVHM RLV Integration Tech (Spiral 3) BASELINE EELV, Shuttle, Aircraft RLV Integration Technology Near Term RLV Integration Tech (Spiral 2) Mid Term Far Term
16 Integrated Systems Health Management IPT Technical Directorate Roles ISHM Integration VA,VS Structures VA, ML Propulsion PR, ML Avionics SN Controls VA, PR Sub-Systems ML, PR, VA Other DE Ground Ops HE, IF, PR Directorate s POC: Mark Derriso (Air Vehicles) Kelly Navarra (Materials & Manufacturing) Brian Beachkofski (Propulsion) Chris Curtis (Human Effectiveness) Mike Wicks (Sensors)
17 Integrated Systems Health Management -Design Impact Study- How Would ISHM Impact the Following?: Structural Design Current Structural Design Philosophy Reduce FOS? Lighter Design? New Structural Design Philosophy Enable Reliability-based (Probabilistic) Design Approach? Reduce reliance on structural redundancy for fail-safety, reduces weight and cost? Full-Scale Structural Fatigue Test Structural/Materials Certification Process Reduce Certification Time? New Structural Maintenance Procedure Enable Condition-Based Maintenance? Structural Inspection
18 AFRL ISHM Conference
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