Download Next Generation Data Acquisition Technologies for Aging Aircraft John Fallon

Next Generation Data Acquisition
Technologies for Aging Aircraft
John Fallon
Curtiss-Wright Controls Avionics & Electronics
(626) 851-3100/[email protected]
Operational Loads
Monitoring (OLM)
A structural usage activity involving the
capture, analysis and reporting of measured
strain data or derived loads plus associated
flight parameters from a sample of
instrumented in-service aircraft within a fleet
Next Generation Data Acquisition
Technologies for Aging Aircraft
OLM for ageing aircraft is of particular importance
when the aircrafts loads or flight profile change.
Lockheed C-130 in 60 Nations
OLM and FTI Data
Requirements
OLM & FTI - Depend on Reliable Data
Number of Parameters
Data Rates
Data Storage
Data Processing
FTI
Thousands
50K to >2M sps
Onboard and telemetered
Real-Time and Post flight
OLM
Thousands
1 – 100 sps
Onboard
Post flight
Flexible COTS Solution
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Lower up-front cost
Lower cost of ownership
New technologies and upgrades can be integrated at low risk
A range of interfaces are available and future standards can be
added
Spares are a standard product and production equipment lead
times are shorter
High quality software is available and thoroughly tested
Systems are flexible, expandable and programmable
Already qualified to environmental standards
Open Standards
Ethernet
– Standard open interfaces and protocols
– Significantly less wiring
– Higher data rates and improved time synchronization
– Reduction of programming and troubleshooting time during install and test
– Reduced cost and ease of integration with COTS equipment
IEEE 1588 Precision Time Protocol (PTP)
– Data can be synchronized across a large
network with a high degree of accuracy
(typically within <100ns)
XidML
– an XML metadata standard for the
aerospace community
Recorder Standards
64GB CF card can hold approximately 1086 hours of data at 8,000 sps
HC-130H
The United States Coast Guard
employs the HC-130H for
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long range search and rescue
drug interdiction
illegal migrant patrols
homeland security
logistics
The life-limiting critical fatigue component for the C130 fleet is the Center Wing Box (CWB), making it a
prime structural focus area
The Problem
Safe useful life of C-130 called in to question following a retrofitted
C-130 fire tanker crash
USAF were finding CWB cracks earlier than predicted by models
The Solution
Carry out an assessment of the effects of
corrosion and fatigue on C-130 CWB
– Teardown retired CWB
– Develop of structural damage management tools
– Collect representative flight data to update and
validate finite element tools
CAStLE RESEARCH
Center for Aircraft Structural Life Extension
Instrumenting HC-130H
Acra KAM-500 DAU monitored
– Wing beam, and other fatigue critical locations (33 strain gages)
– CWB’s thermal environment (11 RTDs)
– Cabin pressure, temperature and humidity (pressure, temperature, and
humidity transducer and remote probe)
– Position, altitude, ground speed, true and magnetic course (GPS receiver)
– Acceleration (2 DC single-axis accelerometers)
– Cabin pressure and aircraft static pressure (2 Precision Pressure
Transducers)
– Flap Position (Sensor)
– True airspeed, weight-on wheels, ramp door position, and flap position
(KAM-500 analog voltage monitoring module)
The KAM-500
Data recorded on power
up
CF cards taken off and
replaced ~ 3 weeks and
sent for data retrieval
2800 hours of data was
collected over 5 years
Operational Benefits #1
Aircraft life extension by 20% for 16 of 26 operational A/C
– Operating environment less severe than originally thought
11% Reduction in Fleet Age
– 3 additional years of life
– Allowed for effective retirement and replacement
Additional environmental data gathered for future corrosion studies
Operational Benefits #2
Modularity
Could be quickly reconfigured and reused on many aircraft
Lightweight Miniature System
Could be easily added to A/C during planned inspection
Live on power up
No need for operator in loop
Integrated High-Density Memory
Only needs to be removed every month
Open Standard Data Format
Allowed for smooth data transfer to LM analysis systems
Emerging Technology
SMART
Sensors
Signal sensing and measurement at sensor
location - reduce wiring requirements.
Wireless, self powered sensors could simplify this further
while nanotechnology, MEMS and computational
advances like artificial intelligence and distributed
computing could eventually lead to self repairing and
ageless structures.
Essential that open system architectures are used in
conjunction with COTS Interfaces.
Conclusion
Many aircraft operators, military and civilian, are keen
to extend the existing lifetime of their current fleet
Use of common, configurable COTS hardware and
software technologies available today can
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reduce the cost of purchase
cost of ownership
support
reliability
maintainability of OLM requirements
The future prospects of fully integrated, smart systems
can be exploited by DAUs with COTS philosophies
Questions
Thank You
www.cwc-ae.com