Demonstrated Capabilities - SAE International

LTU Prognostics

Summary

Demonstrated Capabilities:

ƒ CBM Is Achievable for Electronic Components
ƒ Prognostics Developed Using Existing Buss Data
ƒ Fault Isolation Enabled By Bit Mapping

Benefits to the Warfighter:

ƒ Enhanced Diagnostics and Troubleshooting
ƒ Prediction of Remaining Useful Life (Prognostics)
ƒ Reduction of Unscheduled Maintenance

G3-0407 TraTnrsafnosrfmorimnginAgrAmrmy yAvAivaitaitoionnMMaainintteennaannccee Fromm tthheeIInndduusstrtiraial lAAgegetotothtehIenfIonrfmoramtiaotnioAngeA!ge! 21
9/30/2005

Proof of Principle Results

ƒ Validated Feasibility of Condition Based Maintenance for Aviation

ƒ Demonstrated Benefits

– Reduced Maintenance Manhours
– Increased Readiness
– Potential for Savings and Cost Avoidance

ƒ Sufficient Enabling Technologies Exist to Begin Implementation

ƒ Supporting Processes Can Be Transparent to Soldiers

ƒ Prognostics Are Feasible on Both Dynamic Components and
Electronic Components

ƒ Identified Four Data Classifications to Enable Prognostics

– Field Normal
– Field Abnormal
– Field Maintenance
– Seeded Fault/Bench Testing

G3-0407 TraTnrsafnosrfmorimnginAgrAmrmy yAvAivaitaitoionnMMaainintteennaannccee Fromm tthheeIInndduusstrtiraial lAAgegetotothtehIenfIonrfmoramtiaotnioAngeA!ge! 22
9/30/2005

CBM Enabled Aircraft

KKeennttuucckkyy NNoorrtthhCCaarroolilninaa IIrraaqq KKoorreeaa
FFttCCaammppbbeellll NNaattioionnaallGGuuaarrdd UUSS AArrmmyy UUSS AArrmmyy
116600ththSSOOAARR 88UUHH--6600AA/L/L((PP)) 88 AAHH--6644DD 1155 UUHH--6600AA//LL
1155AAHH--6644AA((PP))
66MMHH--6600KK IIrraaqq
PPAANNaattioionnaall NNaattiioonnaall GGuuaarrdd
TTeennnneesssseeee GGuuaarrdd/E/EAAAATTSS SSoouutthh CCaarroolliinnaa
NNaattioionnaallGGuuaarrdd
11CCHH--4477DD 88 UUHH--6600AA//LL,,
55AAHH--6644AA 33CCHH--4477DD((PP)) 1166 AAHH--6644AA
SSoouutthhCCaarroolilninaa
MMisisssoouurrii NNaattioionnaallGGuuaarrdd IIRRAAQQ//KKuuwwaaiitt
NNaattioionnaallGGuuaarrdd NNaattiioonnaallGGuuaarrdd
22AAHH--6644AA
11AAHH--6644AA KKeennttuucckkyy MMiissssoouurrii
1177AAHH--6644AA((PP)) FFttCCaammppbbeellll 11 UUHH--6600
1122UUHH--6600AA/L/L((PP)) 3300UUHH--6600LL
44AAHH--6644DD
CCaalilfifoorrnniaia AAlalabbaammaa
NNAASSAAAAmmeess NNaattioionnaallGGuuaarrdd
11UUHH--6600TTeesstt 88UUHH--6600AA/L/L
33CCHH--4477DD((PP))
AAirirccrraafftt

AArrizizoonnaa
WWAAAATTSS
55AAHH--6644AA
1155AAHH--6644AA((PP))

AAllaabbaammaa • Over 33 Systems supporting the war
AATTTTCC fighter In IRAQ

11UUHH--6600AA//LL,, 11 AAHH--6644AA,, • Over 40,000 Flight Hours Experience
22 AAHH--6644DD,, 11 CCHH--4477DD

G3-0407 TraTnrsafnosrfmorimnginAgrAmrmy yAvAivaitaitoionnMMaainintteennaannccee Fromm tthheeIInndduusstrtiraial lAAgegetotothtehIenfIonrfmoramtiaotnioAngeA!ge! 23
9/30/2005

Testimony From the Field

“I feel more confident in the reliability of my aircraft.”

SFC, AH-64 Maintenance NCO

“CBM is a great tool used to decrease … schedule & unscheduled
maintenance.”

SGM, Ft Rucker, AL

“[Vibration monitoring] provides early warning of pending failure”

CW4, AH-64 Maintenance Test Pilot

“…allows time to order and to select a convenient time for repair
or replace.”

CW5, Maintenance Test Pilot

“…recommend we adopt CBM ASAP.”

CSM, Ft Hood, TX

G3-0407 TraTnrsafnosrfmorimnginAgrAmrmy yAvAivaitaitoionnMMaainintteennaannccee Fromm tthheeIInndduusstrtiraial lAAgegetotothtehIenfIonrfmoramtiaotnioAngeA!ge! 24
9/30/2005

Potential Benefit to Warfighters

ƒ AH64 Block III Fleet, Conservative Analysis

– 10 Parts
– Reviewed By AMC G-8, DA G-8, and DASA CE
– Readiness +4.9%
– 41,000 Maintenance Manhours (MMHs) Saved
– Equates to an additional AH64 Battalion

ƒ UH60 M Model Fleet, Conservative Analysis

– 9 Parts
– Readiness +3.4%
– 26,000 MMHs Saved

ƒ Spiral Development of Benefits Analysis

G3-0407 TraTnrsafnosrfmorimnginAgrAmrmy yAvAivaitaitoionnMMaainintteennaannccee Fromm tthheeIInndduusstrtiraial lAAgegetotothtehIenfIonrfmoramtiaotnioAngeA!ge! 25
9/30/2005

CBM Implementation Phases

FY 05-07 IOC 2011 FOC 2015
FY 08-15 FOC 2015
PPhhaassee11––CCoonncceeppttDDeevveeloloppmmeenntt
FY 16+
• Proof of Principle
• Develop Data Warehouse PPhhaassee22--ImImpplelemmeennttaattioionn PPhhaassee33--OOppeerraattioionnss
• Develop Prognostics
• Assess Impacts to DOTMLPF • MFAB Fielding • Sustain CBM
• Assure Interoperability With: • Continuous Data Analysis • Continuous Data Analysis
• Refinement of Prognostics • Refine Prognostics
– GCSS-A • Changes to DOTMLPF • DOTMLPF Improvements
– CLOE • Examine New Technologies
– LMP
– PLM+

G3-0407 TraTnrsafnosrfmorimnginAgrAmrmy yAvAivaitaitoionnMMaainintteennaannccee Fromm tthheeIInndduusstrtiraial lAAgegetotothtehIenfIonrfmoramtiaotnioAngeA!ge! 26
9/30/2005

Summary

Challenges:

ƒ Transition From Proof of Principle to Implementation
ƒ Prognostic Algorithm Development
ƒ Integrating With the Automation Architecture

(CLOE, LMP, PLM+, GCSS-A)
ƒ Digital Source Collectors Fielded on Aircraft
ƒ Long-term Commitment to CBM Transformation By

OSD/DA

G3-0407 TraTnrsafnosrfmorimnginAgrAmrmy yAvAivaitaitoionnMMaainintteennaannccee Fromm tthheeIInndduusstrtiraial lAAgegetotothtehIenfIonrfmoramtiaotnioAngeA!ge! 27
9/30/2005