Health Management Technology Integration

1BT_PW_Sub_icon.ppt | 8/4/2004BOEING is a trademark of Boeing Management Company.Copyright © 2006 Boeing. All rights reserved. 1

Boeing Phantom Works

Copyright © 2006 Boeing. All rights reserved.

Support and Services - IVHM

Health Management Technology Integration

Kirby Keller, [email protected], 314-233-2995

Support and ServicesBoeing Phantom WorksThe Boeing Company

Box 516, St. Louis, Mo. 63166

mailto:[email protected]





Agenda

• Change in Business Paradigm: Support and Services is a Product

• Boeing Phantom Works• 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





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.





IVHM is all This Stuff

A.k.aReasoners, 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…





More Terms

• Condition Based Maintenance

• Network Centric Operations (NCO)

• Network Centric Logistics (NCL)

• Performance Based Logistics





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





Data

Off-Vehicle Processing &Data Repository

Maintenance & Logistics• Maintenance Scheduling• Spares Supply• Asset Tracking• Maintenance Execution

Health Status- Current- Predicted

Operations Control• Operational Schedule• Operational Effectiveness

• Operational Demand• Fleet Availability

Fleet Status

Vehicle H/W & S/W Upgrade/Maturation

The IVHM-NCO Vision in AerospaceDesign/ Engineering/Manufacturing

I and DLevel Test And Repair

On-VehicleProcessing





Commercial Airplanes Family

787787787

767767767

747747747

717717717

777777777 737737737

C-17C-17

F-18F-18

ApacheApache

TankersTankers

ISSISS

SatellitesSatellites

DeltaDelta

JTRSJTRS

Advanced SystemsAdvanced Systems

FCSFCS

Integrated Defense Systems

HomelandSecurityHomelandSecurity

Boeing Products





Need for IVHM Varies By Platform

Required Material Performance

Increasing Flight Hours





Boeing Leverages Talent From Around the World

NetherlandsUnited Kingdom

Spain

ItalyUkraine

South Africa

Denmark Germany

Russia

AustraliaIndia Singapore

China





The Boeing Company

BoeingPhantom Works





Phantom Works Support and Services IVHM Group’s Role in Boeing

IVHM Technology: Sensors, Algorithms, ToolsSuppliers: Industry, Government, Academia

End to End Demonstration Systems to Show Proof of Concept and Reduce Risk to Enable Transition

Boeing Business Unit Products

Phantom Works IVHM





Boeing’s Position in IVHM Market Place





Boeing Research Focus

DiagnosticsPrognostics

Propulsion

Electrical

Electronics

MechanicalStructural

Payloads

Architecture

ConOps

Specifications

Transformational

Business Practices

Bes

t pr

actic

es

Systems Integration

NCO/NCL/e-Enabled Integration

Information Integration

IVHM Value Chain

Our R&D is focused on integrating and transitioning technologies though the value chain and into operations

Our R&D is focused on integrating and transitioning technologies though the value chain and into operations

Concept of OperationsConcept of Operations•• Analysis, modeling, optimization and simulation of IVHM impactsAnalysis, modeling, optimization and simulation of IVHM impacts•• Development of key sensor to decisionDevelopment of key sensor to decision--maker user interfacesmaker user interfacesTransformational Business PracticesTransformational Business Practices•• Integration of adaptive control, health management, and autonomoIntegration of adaptive control, health management, and autonomous us

mission management software enabling high confidence operationmission management software enabling high confidence operationInformation IntegrationInformation Integration•• Ground based reasoner algorithms and graphical user interfaceGround based reasoner algorithms and graphical user interface•• Open system interoperability data warehouse Open system interoperability data warehouse •• Data mining processes and toolsData mining processes and toolsBest PracticesBest Practices•• Program implementation, analysis, and integration handbooksProgram implementation, analysis, and integration handbooks•• Programs and technical maturity benchmarkPrograms and technical maturity benchmark•• EndEnd--toto--end design tools, process, and documentationend design tools, process, and documentationArchitectureArchitecture•• Onboard near real time H/W & S/W architectureOnboard near real time H/W & S/W architecture•• DataData--transfertransfer--toto--offboardoffboard architecturearchitectureSystems Integration & Subsystems SpecificationsSystems Integration & Subsystems Specifications•• Development and Integration Center w/integrated tools suite Development and Integration Center w/integrated tools suite •• Subsystems physics models and algorithms Subsystems physics models and algorithms •• Structural damage detection and corrosion models and algorithmsStructural damage detection and corrosion models and algorithms•• Requirements development and subsystem allocationsRequirements development and subsystem allocations

Boeing R&D Focus





A System Integrator’s View of IVHM Integration

$

Customer/Business Requirements

World’s Great Technologies

Product

Design and Development ProcessFor New A/C or Legacy Upgrade

Constraints: Weight, Cost, Schedule





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





Breaking Rule #1 - Integration IVHM into Vehicle Avionics

Support CriticalSensor

Support CriticalProcessing &Data Storage

Support CriticalProcessing Capability

Support CriticalData Bus

Data Communication /Transportation (e.g., Wireless, Transfer device)

Access to Subsystem Data

System/Subsystem/Component

DigitalController

Core Processing Comm

Link

Data Transfer Device

Flight Critical ControlBus(es)

Actuator

Engine

Gear Box

Pump

Battery

Generator

DataCollection

CommEquipm’t Decision

Makers- Operations- Maintenance- Logistics

GroundProcessing

Fault Code

• AdvancedDiagnostics• Usage• Prognostics• Supporting Data

Need for Health Ready Subsystem/Systems





Integrating IVHM into the Support Infrastructure

Fault Codes From A/C or Cartridge Download

Tech OrdersFault Isolation ManualRepair Manual

Approved Data

System

Fault Code is a Pointer to a Fault Isolation ProcedureAnd It’s the Law

Update InformationSystem

• AdvancedDiagnostics• Usage• Prognostics• Supporting Data

Update TechOrders





Traditional Vehicle/Fleet Concept of Operation

Fault OccursCockpit Indication

Crew reports to Ground

Plane Lands

Work OrderCreated

Troubleshoot

• Get Spares• Fix Problem

In worst case;- Repair parts and/or support equipment not available- Airplane remains on ground, unavailable for extended time, operations schedule upset

Hrs





Vehicle Concept of Operation with Accurate Diagnostics & ‘Fault Forwarding’

Fault OccursCockpit Indication

Crew/Onboard System reports to Ground

Plane Lands

Work OrderCreated

Trouble shooting(Minimized)

Fix Problem

• No wait for Parts or Equipment• Minimize Trouble Shooting• Need Accurate Diagnostics/Prognostics

Possible Maintenance RequirementsDetermined

Parts Availability Check

• Generate possible outcomes• Determine Best Courses of ActionRequires:

• Data Download• Accurate Diagnostics/Prognostics• Network Centric Logistics• Distributed Information System and Decision Aiding

• Mx Personnel Trained• Parts Ready• Delay reconciled in ops schedule

Hrs





Ideal Vehicle Concept of Operation with Accurate Prognostics

Leave Arrive, Make Money

No/Less Surprises,Maintenance Done on Opportunistically,On Condition





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





Multiple Suppliers Require Integrated IVHM Analysis and Development Environment

Supplier #1 Supplier #2 Supplier #M

Supplier #K Supplier #J Supplier #N

Health MgmtIntegration- Analysis- Design- System Software





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 Requirements3. Fitting IVHM into the Organization4. Including IVHM in the Vehicle Design, the Cost of

Add-On IVHM and Health Ready Subsystems5. Supporting Critical vs Mission or Flight Critical 6. Integration of IVHM Elements Within and Off the

Vehicle7. Getting Data Off the Platform (In-Flight, On Ground)8. Integrating IVHM with Operational Decision Making -

Realizing the Gain9. Regulation Barriers and Legacy Infrastructure (Fault

Isolation Manuals, Data Systems)10. What is the Business Case for the Parties Involved?





Phantom Works Support and Services IVHM Group’s Role in Boeing

IVHM Technology: Sensors, Algorithms, ToolsSuppliers: Industry, Government, Academia

End to End Demonstration Systems to Show Proof of Concept and Reduce Risk to Enable Transition

Boeing Business Unit Products

Phantom Works IVHM- Program Analysis and Modeling- Development Laboratory- Operations Laboratory





Phantom Works IVHM LabsThe IVHM laboratories being developed by Boeing PW are a means to transition

technology to Boeing Products.

OperationalEnvironment

Program Analysis & Modeling

EnvironmentDevelopmentEnvironment

WHAT to build? HOW to build?

How to Use?Risk Reduction





Providing a competitive engineering

methodology for future and legacy platforms

Health Management Technology Delivery

Program Analysis

and Modeling

Environment

Development Environment

OperationalEnvironment

Flight andIn-service

Demonstrations

Concepts

ProductReqmts

TraceableDevelopment

PracticalImplementation

Command

Operations

Maintenance





Program Analysis and Modeling Environment: Cost/Benefit

••On/Off board tradesOn/Off board trades

••Configuration tradesConfiguration trades

••Embedded/Federated TradesEmbedded/Federated TradesTornado Diagram

Solution #2 Solution #1

Probability Curves

Solution #2 Solution #1

Probability Curves

+

-

$

CostBenefitNPV

Value Waterfall

+

-

$

CostBenefitNPV

Value Waterfall

Expected NPV

Prob

abili

ty o

f Suc

cess

Portfolio Analysis

Expected NPV

Prob

abili

ty o

f Suc

cess

Portfolio Analysis

Not Mission Capable Maintenance Drivers

Look

Pha

se o

fS

ched

uled

Insp

ectio

ns

Turb

ofan

Prop

ulsi

on S

yste

m

Land

ing

Gea

r

Flig

ht C

ontro

lSy

stem

Airfr

ame

Air

Con

ditio

ning

/Bl

eed

Air/P

ress

ure

Fuel

Sys

tem

Auto

Flig

ht

Look

Pha

se o

fSp

ecia

l Ins

pect

ions

NM

CM

Hou

rs

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Cum

Per

cent

of T

otal

Organization-Level Maintenance Manhour Drivers

Look

Pha

se o

fSp

ecia

l Ins

pect

ions

Look

Pha

se o

fSc

hedu

led

Insp

ectio

ns

Turb

ofan

Pro

puls

ion

Syst

em Airfr

ame

Land

ing

Gea

r

Flig

ht C

ontro

lSy

stem

Air C

ondi

tioni

ng/

Blee

d A

ir/Pr

essu

re

Fuse

lage

Ligh

ting

Mis

cella

neou

sU

tiliti

es

O-L

evel

MM

H

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Cum

Per

cent

of T

otal

Ao Drivers

Mx Drivers

Performancerequirements

ReliabilitySchedule

Maintainability

Cost

Technicalparameters Producibility

•• Fleet SimulationFleet Simulation

•• Health Ready Technology Health Ready Technology ImpactImpact

•• MeasurandsMeasurands: Maintenance : Maintenance Costs, Availability, Gate Costs, Availability, Gate Departure Rate, No Fault Found. Departure Rate, No Fault Found. FREQUENT

PROBABLE

OCCASSIONAL

REMOTE

IMPROBABLE

CATASTCRITI

MAN

0

10

20

30

40

50

60

70

80

90

QUANTITIES

FMEA CRITICALITY MATRIX





Feature Comparison with Fleet Simulation





IVHM Development Lab Activities

IVHM Application IVHM Application IntegrationIntegration

IVHM Capability IVHM Capability DemonstrationsDemonstrations

IVHM Systems IVHM Systems Engineering ProcessEngineering Process

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.

Deliver FuelTurn On Pump

Open Valve

Shutoff Fuel (OR)Turn Off Pump

Close Valve

Monitor System HealthMonitor Pump Pressure

Monitor System HealthMonitor Valve Position (Open, Closed)

Provide BasicPower to Pump

Turn On Pump, Turn_Off_PumpCommand Pump On (H, M, L)

Command Pump Off

Provide BasicPower to Valve

Open Valve, Close ValveCommand Valve Open

Command Valve Closed

Monitor System HealthMonitor PC BIT Status

(Major, Minor, Overheat, Parity)

RIU-PSDeg, Open

RIU-XSDeg, Open

PDU-PPwrDeg, Open,

Shorted

RIU-PCmdA/B

Shi, Slo

PDU-VPwrDeg, Open,

Shorted

RIU-VCmdShi, Slo

RIU-PC_Parity, Status A/B

Shi, Slo

XSensSmax, Szero

PSensDeg, Open

No Operation, Shorted Winding, Degraded Bearing , Degraded Stator,

Ext Leaking, Int LeakingCntl NoOp, Cntl Spurious Op

Stuck Open, Stuck Closed, Sticking, Ext Leaking, Int Leaking

0 = Close1 = Open

zero = Closedmax = Open

P,QP,Q

P,Q

PCmd

PPwr VPwr

VCmd0 = Off1 = On

0 = Off1 = On

0 = Close1 = Open

PCBIT

CM03 (CVCR)CM04 (CVOR)IVHM07 (FVCR)IVHM08 (FVOR)CM09 (RIU BIT)

CM06 (RIU BIT) CM07 (RIU BIT)

IVHM03 (PPM)CM11 (PDU BIT)

CM01 (No Gnd StdbyP)CM02 (No Gnd OperP)IVHM01 (Lo Flt OpP)IVHM02 (Hi Flt OpP)CM13 (PSense Range)CM10 (RIU BIT)

CM12 (PDU BIT)

CM05 (PC Major)IVHM04 (PC Parity)IVHM05 (PC Minor)IVHM06 (P OverHeat)CM08 (RIU BIT)

Deliver FuelTurn On Pump

Open Valve

Shutoff Fuel (OR)Turn Off Pump

Close Valve

Monitor System HealthMonitor Pump Pressure

Monitor System HealthMonitor Valve Position (Open, Closed)

Provide BasicPower to Pump

Turn On Pump, Turn_Off_PumpCommand Pump On (H, M, L)

Command Pump Off

Provide BasicPower to Valve

Open Valve, Close ValveCommand Valve Open

Command Valve Closed

Monitor System HealthMonitor PC BIT Status

(Major, Minor, Overheat, Parity)

RIU-PSDeg, Open

RIU-XSDeg, Open

PDU-PPwrDeg, Open,

Shorted

RIU-PCmdA/B

Shi, Slo

PDU-VPwrDeg, Open,

Shorted

RIU-VCmdShi, Slo

RIU-PC_Parity, Status A/B

Shi, Slo

XSensSmax, Szero

PSensDeg, Open

No Operation, Shorted Winding, Degraded Bearing , Degraded Stator,

Ext Leaking, Int LeakingCntl NoOp, Cntl Spurious Op

Stuck Open, Stuck Closed, Sticking, Ext Leaking, Int Leaking

0 = Close1 = Open

zero = Closedmax = Open

P,QP,Q

P,Q

PCmd

PPwr VPwr

VCmd0 = Off1 = On

0 = Off1 = On

0 = Close1 = Open

PCBIT

CM03 (CVCR)CM04 (CVOR)IVHM07 (FVCR)IVHM08 (FVOR)CM09 (RIU BIT)

CM06 (RIU BIT) CM07 (RIU BIT)

IVHM03 (PPM)CM11 (PDU BIT)

CM01 (No Gnd StdbyP)CM02 (No Gnd OperP)IVHM01 (Lo Flt OpP)IVHM02 (Hi Flt OpP)CM13 (PSense Range)CM10 (RIU BIT)

CM12 (PDU BIT)

CM05 (PC Major)IVHM04 (PC Parity)IVHM05 (PC Minor)IVHM06 (P OverHeat)CM08 (RIU BIT)

Requirements Development• requirements analysis• requirements verification

Requirements Development• requirements analysis• requirements verification

Design Synthesis & Integration• detailed trade studies, system models• IVHM analysis – predictions, correlations

Design Synthesis & Integration• detailed trade studies, system models• IVHM analysis – predictions, correlations

System Test & Evaluation• verification, qualification, integration• system approaches to risk mitigation

IVHM System Maturation•Implement root cause analysis and corrective action resources

System/Functional Analysis• initial trade studies• models• simulation

System/Functional Analysis• initial trade studies• models• simulation

Monitor & Control

• Technical rqmts

• Supplier rqmts

• Processes• Interfaces

Vehicle Operational & Support

Goals

Vehicle Operational & Support

Goals

Safe & Affordable

Vehicle

Safe & Affordable

Vehicle





Development Lab: Tool Integration

IVHM IVHM Common Common

RepositoryRepositoryDesign

Reliability

Testability

Safety

Onboard Diagnostics

Offboard Diagnostics

Detailed Test Development Maintenance

Procedures

IPT Desktop Users

IVHM IVHM Common Common

RepositoryRepositoryDesignDesign

ReliabilityReliability

TestabilityTestability

SafetySafety

Onboard Diagnostics

Onboard Diagnostics



Detailed Test DevelopmentDetailed Test Development Maintenance

ProceduresMaintenance Procedures

IPT Desktop UsersIPT Desktop Users

• IPT – Integrated Product Team• IVHM Process Description





IVHM Tool Chain Concept

Discrete SuperBlockBIT_PC_0001

Sample Period0.05

Sample Skew0.

Inputs6

Outputs5

Enable SignalParent

GroupId0

AND

SD_Enable_Log OR 5

SD_Out_LogAND 4

BIT_PC_0001BIT_PC_0001_TE_Log

BIT_PC_0001_RE_LogPCount

RCount

SCount

Cond Out

Last InIn

Last Out0.05

SUPER

BLOCK

Lib_IVHM_Persist_Latch_Logic1

23

NOT

=1S=2S=3S=4S=5S=6S=7S=8S=9S=10S

Constant

H

Persistence_Constants

3

=1

=2

=3

=4

=5

Constant

H

Latching_Constants

3

=1

=5

=10

=15

=20

Constant

H

Stale_Frame_Constants

5

=On

=OffConstant

H

External_Output_Enable

1

3 T2L_BstPump_StatusA

4 T2L_BstPump_StatusA

1 T2L_BstPump_CmdA

2 T2L_BstPump_CmdB5

5 BE0005_T2L_XfrPump_Major_Fail

4

6 BIT_PC4_Invalid_Log

1

23

Required Tests

Test/Math Modeling Tools:MatLab, MatrixX, …

Development Tools: TFPG, Other Model Based Tools, …

Failure Dependencies(Models)

• IVHM MonitorAutoCode

Onboard/Offboard S/W

OSACBM

• Fault IsolationAutocode

Ground BasedS/W

• Refinement of Diagnosis (Maint History)

• Logistics Tools

Diagnosis

Analysis Tools: ADVISE, Other Analysis Tools, …

BIT Analysis/FMECA

Failure Dependencies (Rules, Bayesian)





Tool Integration: Proof of Concept

TRANSDUCER

#2 SIGNAL PROCESSING

#3 CONDITION MONITOR

DATA ACQUISITION

#4 HEALTH ASSESSMENT

#6 DECISION SUPPORT

#7 PRESENTATION

#1 SENSOR MODULE

#5 PROGNOSTICS

HTTPXML

HTTPXML

HTTPXML

RTCORBA

C

o

m

m

N

e

t

w

o

r

k

RTCORBA

RTCORBA

XML-RTCORBA

TRANSDUCER

#2 SIGNAL PROCESSING

#3 CONDITION MONITOR

DATA ACQUISITION

#4 HEALTH ASSESSMENT

#6 DECISION SUPPORT

#7 PRESENTATION

#1 SENSOR MODULE

#5 PROGNOSTICS

HTTPXML

HTTPXML

HTTPXML

RTCORBA

C

o

m

m

N

e

t

w

o

r

k

RTCORBA

RTCORBA

XML-RTCORBA





Top Level Functional View of the Operational Environment





Facility for Integration and Research of Subsystems (FIRST)





Data Generation for Fault Characterization





End to End IVHM Demonstrations with Hardware in the Loop

Subsystems LaboratoryFIRST Facility

Fiber OpticLink

IVHM & Enterprise Prototyping & Integration Center (EPIC) Laboratories

Network Centric Operations andLogistics Integration Centers





IVHM Data Accessible for Development and Maturation (Integrated Airplane Health Management)





The Boeing IVHM Laboratory is becoming a Virtual Facility To Leverage the Resources of Industry, Academia and Gov’t.

Seattle

Huntington Beach

MesaSt. Louis

(Current IVHM Lab Site)

Customer

Supplier

Boeing Site

Access to:• Integration Framework (OSACBM)• Stored Data• Hardware in the Loop• End to End Demonstrations





Health Management Engineering Environment – Concept to Technology Transition





• Questions, Comments?

Health Management Technology Integration

Documents