Health Management Technology Integration

Health Management Technology Integration Kirby Keller, kirby.j.keller@boeing.com, 314-233-2995 Support and Services The Boeing Company Box 516, St. Louis, Mo. 63166 1BT_PW_Sub_icon.ppt 8/4/2004 1

Agenda Change in Business Paradigm: Support and Services is a Product Boeing Role in IVHM Community: Harvest Technology Some Challenges to Implementation Tools and Laboratories to Make the Business Case, Promote Efficient Development and Perform Risk Reduction Demonstrations Guideline to Transition IVHM: Follow the Money 2BT_PW_Sub_icon.ppt 8/4/2004 2

Definitions Integrated Vehicle Health Management is the transformation of system data into information to support operational decisions that results in: Reduced life cycle costs Minimized maintenance actions Reduced redundancies Improved readiness and availability of Expensive, Complex Vehicles. 3BT_PW_Sub_icon.ppt 8/4/2004 3

IVHM is all This Stuff A.k.a Reasoners, Algorithms, Prognostics, Predictive Maintenance, Incipient Failure Detection, Failure On Set Detection (FOSD), Gray Scale Health, Diagnostics, Integrated Diagnostics (ID), Enhanced Diagnostics, Bayesian Reasoners, Anomaly Detection, Ground Based Reasoners, Fault Forwarding, Adaptive Control, Contingency Management, Prognostics And Health Management (P&HM, PHM), Condition Based Maintenance (CBM, CBM+), Health And Utilization Monitoring System (HUMS), Structural Utilization Monitoring System (SUMS), Integrated Vehicle Health Management (IVHM), Integrated Systems Health Management (ISHM), Airplane Health Management (AHM), Integrated Airplane Health Management (IAHM), Automated Maintenance Environment (AME), Structural Health Management (SHM), Health Management, Vehicle Health Management, Systems Health Management 4BT_PW_Sub_icon.ppt 8/4/20044

More Terms Condition Based Maintenance Network Centric Operations (NCO) Network Centric Logistics (NCL) Performance Based Logistics 5BT_PW_Sub_icon.ppt 8/4/2004 5

How to Make Money with Diagnostics/ Prognostics (IVHM)? Old Paradigm Sell Vehicles (Aircraft) Sell Spares Operator Owns Vehicle Fleet, Maintains Vehicles and Provides Crew New Paradigm Sell Guaranteed Service Gate Dispatch Reliability Seat Miles Power by the Hour (Rolls-Royce) Service Provider May Own Fleet, Maintains Fleet Operator Provides Crew 6BT_PW_Sub_icon.ppt 8/4/2004 6

The IVHM-NCO Vision in Aerospace Design/ Engineering/ Manufacturing Vehicle H/W & S/W Upgrade/Maturation I and D Level Test And Repair On-Vehicle Processing Operations Control Operational Schedule Operational Effectiveness Operational Demand Fleet Availability Fleet Status Data Maintenance & Logistics Maintenance Scheduling Spares Supply Asset Tracking Maintenance Execution Health Status - Current - Predicted Off-Vehicle Processing & Data Repository 7BT_PW_Sub_icon.ppt 8/4/2004 7

Boeing Products Homeland Security F-18 FCS 767 717 C-17 ISS Delta 787 747 JTRS Advanced Systems Apache Satellites 777 737 Commercial Airplanes Family Tankers Integrated Defense Systems 8BT_PW_Sub_icon.ppt 8/4/2004 8

Need for IVHM Varies By Platform Required Material Performance Increasing Flight Hours 9BT_PW_Sub_icon.ppt 8/4/2004 9

Boeing Leverages Talent From Around the World United Kingdom Netherlands Denmark Germany Italy Ukraine Russia Spain China South Africa India Singapore Australia 10BT_PW_Sub_icon.ppt 8/4/2004 10

The Boeing Company Boeing Phantom Works 11BT_PW_Sub_icon.ppt 8/4/2004 11

Phantom Works Support and Services IVHM Group s Role in Boeing Boeing Business Unit Products End to End Demonstration Systems to Show Proof of Concept and Reduce Risk to Enable Transition Phantom Works IVHM IVHM Technology: Sensors, Algorithms, Tools Suppliers: Industry, Government, Academia 12BT_PW_Sub_icon.ppt 8/4/2004 12

Boeing s Position in IVHM Market Place 13BT_PW_Sub_icon.ppt 8/4/2004 13

Boeing Research Focus IVHM Value Chain Boeing R&D Focus Best practices NCO/NCL/e-Enabled Integration Information Integration Payloads Systems Integration Propulsion Electronics Diagnostics Prognostics Structural Electrical Mechanical Architecture ConOps Specifications Transformational Business Practices Concept of Operations Analysis, modeling, optimization and simulation of IVHM impacts Development of key sensor to decision-maker user interfaces Transformational Business Practices Integration of adaptive control, health management, and autonomous us mission management software enabling high confidence operation Information Integration Ground based reasoner algorithms and graphical user interface Open system interoperability data warehouse Data mining processes and tools Best Practices Program implementation, analysis, and integration handbooks Programs and technical maturity benchmark End-to to-end design tools, process, and documentation Architecture Onboard near real time H/W & S/W architecture Data-transfer transfer-to-offboardoffboard architecture Systems Integration & Subsystems Specifications Development and Integration Center w/integrated tools suite Subsystems physics models and algorithms Structural damage detection and corrosion models and algorithms Requirements development and subsystem allocations Our Our R&D R&D is is focused on on integrating and and transitioning technologies though the the value value chain chain and and into into operations 14BT_PW_Sub_icon.ppt 8/4/2004 14

A System Integrator s View of IVHM Integration World s Great Technologies Customer/ Business Requirements Design and Development Process For New A/C or Legacy Upgrade Product $ Constraints: Weight, Cost, Schedule 15BT_PW_Sub_icon.ppt 8/4/2004 15

Rule #1 If IT does not help Fly the Plane and Complete the Mission, LEAVE IT ON THE GROUND. Troubleshooting and Maintenance are a Ground Thing Rule #2 Do not Underestimate Rule #1 16BT_PW_Sub_icon.ppt 8/4/2004 16

Breaking Rule #1 - Integration IVHM into Vehicle Avionics System/ Subsystem/ Component Engine Actuator Gear Box Pump Battery Generator Support Critical Sensor Support Critical Processing & Data Storage Digital Controller Access to Subsystem Data Flight Critical Control Bus(es) Support Critical Data Bus Core Processing Data Collection Support Critical Processing Capability Comm Equipm t Comm Link Data Transfer Device Data Communication /Transportation (e.g., Wireless, Transfer device) Ground Processing Advanced Diagnostics Usage Prognostics Supporting Data Fault Code Decision Makers - Operations - Maintenance - Logistics Need for Health Ready Subsystem/Systems 17BT_PW_Sub_icon.ppt 8/4/2004 17

Integrating IVHM into the Support Infrastructure Fault Codes From A/C or Cartridge Download Advanced Diagnostics Usage Prognostics Supporting Data Update Tech Orders Tech Orders Fault Isolation Manual Repair Manual Update Information System Approved Data System Fault Code is a Pointer to a Fault Isolation Procedure And It s the Law 18BT_PW_Sub_icon.ppt 8/4/2004 18

Traditional Vehicle/Fleet Concept of Operation Crew reports to Ground Hrs Work Order Created Get Spares Fix Problem Fault Occurs Cockpit Indication Plane Lands Troubleshoot In worst case; - Repair parts and/or support equipment not available - Airplane remains on ground, unavailable for extended time, operations schedule upset 19BT_PW_Sub_icon.ppt 8/4/2004 19

Vehicle Concept of Operation with Accurate Diagnostics & Fault Forwarding Crew/Onboard System reports to Ground Parts Availability Check Work Order Created Hrs No wait for Parts or Equipment Minimize Trouble Shooting Need Accurate Diagnostics/Prognostics Fix Problem Fault Occurs Cockpit Indication Possible Maintenance Requirements Determined Mx Personnel Trained Parts Ready Delay reconciled in ops schedule Generate possible outcomes Determine Best Courses of Action Requires: Data Download Accurate Diagnostics/Prognostics Network Centric Logistics Distributed Information System and Decision Aiding Plane Lands Trouble shooting (Minimized) 20BT_PW_Sub_icon.ppt 8/4/2004 20

Ideal Vehicle Concept of Operation with Accurate Prognostics Leave Arrive, Make Money No/Less Surprises, Maintenance Done on Opportunistically, On Condition 21BT_PW_Sub_icon.ppt 8/4/2004 21

Need for IVHM Processes and Tools to Flow Down Requirements and Make the Business Case Fault Detection X%, Fault Isolation Y%, Can Not Duplicates/No Fault Founds Z% No Fault Founds per Flight Hr Maintenance Main Hours Turn Around Time Mission Capable Rate Gate Dispatch Reliability Mission Reliability (Include Diversion/Aborts) Periods of Maintenance Free Operation 22BT_PW_Sub_icon.ppt 8/4/2004 22

Multiple Suppliers Require Integrated IVHM Analysis and Development Environment Supplier #1 Supplier #2 Supplier #M Health Mgmt Integration - Analysis -Design - System Software Supplier #K Supplier #J Supplier #N 23BT_PW_Sub_icon.ppt 8/4/2004 23

Summary: 10 Challenges of Getting IVHM Onto a Platform and Into Enterprise ConOps 1. Making the Business Case to the Customer 2. Specification and Flowdown of IVHM Requirements 3. Fitting IVHM into the Organization 4. Including IVHM in the Vehicle Design, the Cost of Add-On IVHM and Health Ready Subsystems 5. Supporting Critical vs Mission or Flight Critical 6. Integration of IVHM Elements Within and Off the Vehicle 7. Getting Data Off the Platform (In-Flight, On Ground) 8. Integrating IVHM with Operational Decision Making - Realizing the Gain 9. Regulation Barriers and Legacy Infrastructure (Fault Isolation Manuals, Data Systems) 10. What is the Business Case for the Parties Involved? 24BT_PW_Sub_icon.ppt 8/4/2004 24

Phantom Works Support and Services IVHM Group s Role in Boeing Boeing Business Unit Products End to End Demonstration Systems to Show Proof of Concept and Reduce Risk to Enable Transition Phantom Works IVHM - Program Analysis and Modeling - Development Laboratory - Operations Laboratory IVHM Technology: Sensors, Algorithms, Tools Suppliers: Industry, Government, Academia 25BT_PW_Sub_icon.ppt 8/4/2004 25

Phantom Works IVHM Labs The IVHM laboratories being developed by Boeing PW are a means to transition technology to Boeing Products. How to Use? Risk Reduction Operational Environment Program Analysis & Modeling Environment WHAT to build? Development Environment HOW to build? 26BT_PW_Sub_icon.ppt 8/4/2004 26

Health Management Technology Delivery Program Analysis and Modeling Environment Development Environment Operational Environment Flight and In-service Demonstrations Command Operations Practical Implementation Maintenance Traceable Development Concepts Product Reqmts Providing a competitive engineering methodology for future and legacy platforms 27BT_PW_Sub_icon.ppt 8/4/2004 27

Program Analysis and Modeling Environment: Cost/Benefit NMCM Hours Not Mission Capable Maintenance Drivers Ao Drivers 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% Tornado Diagram Solution #2 Solution #1 Probability Curves On/Off board trades Configuration trades Embedded/Federated Trades Look Phase of Scheduled Inspections Turbofan Propulsion System Landing Gear Flight Control System Airframe Air Conditioning/ Bleed Air/Pressure Fuel System Auto Flight Look Phase of Special Inspections Cum Percent of Total O-Level MMH Organization-Level Maintenance Manhour Drivers Mx Drivers 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% Cum Percent of Total + $ Cost Benefit NPV Value Waterfall Probability of Success Portfolio Analysis Technical parameters Schedule Performance requirements Cost Maintainability Producibility Reliability Look Phase of Special Inspections Look Phase of Scheduled Inspections Turbofan Propulsion System Airframe Landing Gear Flight Control System Air Conditioning/ Bleed Air/Pressure Fuselage Lighting Miscellaneous Utilities - Expected NPV Fleet Simulation 90 Q 80 U 70 A 60 N T 50 I 40 T I 30 E 20 S 10 0 FREQUENT FMEA CRITICALITY MATRIX PROBABLE OCCASSIONAL REMOTE IMPROBABLE N MA CRITI CATAST Health Ready Technology Impact Measurands: : Maintenance Costs, Availability, Gate Departure Rate, No Fault Found. 28BT_PW_Sub_icon.ppt 8/4/2004 28

Feature Comparison with Fleet Simulation 29BT_PW_Sub_icon.ppt 8/4/2004 29

IVHM Development Lab Activities IVHM Systems Engineering Process IVHM Application Integration IVHM Capability Demonstrations Vehicle Operational & Support Goals Requirements Development requirements analysis requirements verification System/Functional Analysis initial trade studies models simulation Design Synthesis & Integration detailed trade studies, system models IVHM analysis predictions, correlations Monitor & Control Technical rqmts Supplier rqmts Processes Interfaces Turn On Pump, Turn_Off_Pump Open Valve, Close Valve Command Pump On (H, M, L) Command Valve Open Command Pump Off Command Valve Closed PCmd RIU-PCmd CM06 (RIU BIT) VCmd 0 = Off 0 = Close RIU-VCmd 1 = On A/B 1 = Open Shi, Slo Shi, Slo Provide Basic Provide Basic Power to Pump Power to Valve 0 = Off 0 = Close 1 = On 1 = Open PPwr IVHM03 (PPM) VPwr PDU-PPwr CM11 (PDU BIT) PDU-VPwr Deg, Open, Deg, Open, Shorted Shorted P,Q P,Q Monitor System Health Monitor Valve Position (Open, Closed) CM03 (CVCR) CM04 (CVOR) CM07 (RIU BIT) IVHM07 (FVCR) RIU-XS IVHM08 (FVOR) Deg, Open CM09 (RIU BIT) CM12 (PDU BIT) zero = Closed max = Open XSens Deliver Fuel Smax, Szero Turn On Pump Open Valve P,Q System Test & Evaluation verification, qualification, integration system approaches to risk mitigation No Operation, Shorted Winding, Degraded Bearing, Degraded Stator, Ext Leaking, Int Leaking Cntl NoOp, Cntl Spurious Op Stuck Open, Stuck Closed, Sticking, Ext Leaking, Int Leaking Shutoff Fuel (OR) Turn Off Pump Close Valve Safe & Affordable Vehicle IVHM System Maturation Implement root cause analysis and corrective action resources PC BIT RIU-PC_Parity, Status A/B Shi, Slo Monitor System Health Monitor PC BIT Status (Major, Minor, Overheat, Parity) CM05 (PC Major) IVHM04 (PC Parity) PSens IVHM05 (PC Minor) IVHM06 (P OverHeat) Deg, Open CM08 (RIU BIT) Monitor System Health Monitor Pump Pressure CM01 (No Gnd StdbyP) CM02 (No Gnd OperP) IVHM01 (Lo Flt OpP) RIU-PS IVHM02 (Hi Flt OpP) CM13 (PSense Range) Deg, Open CM10 (RIU BIT) Provide programs with a sound methodology for incorporating IVHM into their products. Process Handbooks for Programs. Provide a plug & play environment for integrating IVHM tools. Demonstrate the state of the art as it evolves to illustrate how to develop practical IVHM applications. 30BT_PW_Sub_icon.ppt 8/4/2004 30

Development Lab: Tool Integration Reliability Safety Detailed Test Development Maintenance Procedures Design IVHM Common Repository Onboard Diagnostics Testability Offboard Diagnostics IPT Desktop Users IPT Integrated Product Team IVHM Process Description 31BT_PW_Sub_icon.ppt 8/4/2004 31

Persistence_Constants H Constant OR SD_Enable_Log 5 =1S =2S =3S =4S =5S =6S =7S =8S =9S =10S Latching_Constants =1 =2 H =3 Constant =4 =5 NOT AND Stale_Frame_Constants =1 =5 H =10 Constant =15 =20 External_Output_Enable =On H Constant AND SD_Out_Log 4 =Off 1 3 3 5 Lib_IVHM_Persist_Latch_Logic BIT_PC_0001 1 BIT_PC_0001_TE_Log 2 BIT_PC_0001_RE_Log 3 PCount SUPER RCount SCount BLOCK Cond Out Last In In 0.05 Last Out IVHM Tool Chain Concept Analysis Tools: ADVISE, Other Analysis Tools, Development Tools: TFPG, Other Model Based Tools, OSACBM Onboard/Offboard S/W Failure Dependencies (Models) IVHM Monitor AutoCode Fault Isolation Autocode BIT Analysis/ FMECA Required Tests Discrete SuperBlock BIT_PC_0001 1 T2L_BstPump_CmdA Sample Period Sample Skew 0.05 0. 2 T2L_BstPump_CmdB 5 3 T2L_BstPump_StatusA 4 T2L_BstPump_StatusA Inputs Outputs 6 5 Enable Signal GroupId Parent 0 5 BE0005_T2L_XfrPump_Major_Fail 4 32BT_PW_Sub_icon.ppt 8/4/2004 32 6 BIT_PC4_Invalid_Log Test/Math Modeling Tools: MatLab, MatrixX, Failure Dependencies (Rules, Bayesian) Ground Based S/W Diagnosis Refinement of Diagnosis (Maint History) Logistics Tools

Tool Integration: Proof of Concept #7 PRESENTATION #6 DECISION SUPPORT #5 PROGNOSTICS #4 HEALTH ASSESSMENT #3 CONDITION MONITOR #2 SIGNAL PROCESSING DATA ACQUISITION #1 SENSOR MODULE TRANSDUCER HTTP XML HTTP XML HTTP XML XML-RT CORBA RT CORBA RT CORBA RT CORBA C o m m N e t w o r k 33BT_PW_Sub_icon.ppt 8/4/2004 33

Top Level Functional View of the Operational Environment 34BT_PW_Sub_icon.ppt 8/4/2004 34

Facility for Integration and Research of Subsystems (FIRST) 35BT_PW_Sub_icon.ppt 8/4/2004 35

Data Generation for Fault Characterization 36BT_PW_Sub_icon.ppt 8/4/2004 36

End to End IVHM Demonstrations with Hardware in the Loop Subsystems Laboratory FIRST Facility Fiber Optic Link IVHM & Enterprise Prototyping & Integration Center (EPIC) Laboratories Network Centric Operations and Logistics Integration Centers 37BT_PW_Sub_icon.ppt 8/4/2004 37

IVHM Data Accessible for Development and Maturation (Integrated Airplane Health Management) 38BT_PW_Sub_icon.ppt 8/4/2004 38

The Boeing IVHM Laboratory is becoming a Virtual Facility To Leverage the Resources of Industry, Academia and Gov t. Seattle Huntington Beach Mesa St. Louis (Current IVHM Lab Site) Boeing Site Customer Supplier Access to: Integration Framework (OSACBM) Stored Data Hardware in the Loop End to End Demonstrations 39BT_PW_Sub_icon.ppt 8/4/2004 39

Health Management Engineering Environment Concept to Technology Transition 40BT_PW_Sub_icon.ppt 8/4/2004 40

Questions, Comments? 41BT_PW_Sub_icon.ppt 8/4/2004 41