A Hybrid Approach to EMA Prognostics (EMAP) for Engine and Aerospace Applications

Impact Technologies, in collaboration with our OEM partners, proposes to develop a hybrid approach for real-time prognostics of electromechanical actuators (EMAs) that will advance the state-of-the-art in prognostics technologies and help enable the use of EMAs in high power applications. The overall approach will feature a high fidelity dynamic model of various subsystems to virtually sense parameters that can be used to detect degradation, isolate probable root cause, and assess severity. In addition, data-driven techniques will also complement the model-based approach, including approaches related to command-response error analysis and dynamic features. A system level reasoner, featuring advanced diagnostics, prognostics, and knowledge fusion algorithms, will then be implemented within a probabilistic framework. Model order reduction and uncertainty management will also be addressed in future phases to facilitate use within an embedded, on-board implementation. The effort will strive to use the existing sensors that are already available on the aircraft for control, thus limiting the complexity, cost, and weight associated with fielding the system. Experimental validation efforts will be performed within the available Impact and OEM facilitates. This automated, prognostic package will significantly enhance the ability to safely operate aircraft, schedule maintenance activities, optimize operational life cycles, and reduce support costs. BENEFIT: Improvements to the current state-of-the-art in actuator diagnostics is needed to reap the benefits of EMA technologies for high power (>10 kilowatts) applications and avoid “cannot duplicate” failure notifications and improve maintainability. With the successful developments and implementation of this effort, it is strongly anticipated that the prototype algorithms and software module will fulfill this need and be of significant benefit to the F-35 and other DoD applications. Availability improvements will be realized through the reduction of recurring and nonrecurring PHM actions on actuator systems. The realization of such an automated, prognostic reasoning package will significantly enhance the maintainer’s ability to schedule maintenance activities, optimize operational life cycles, and reduce the overall logistics footprint. Better diagnosis of actuation systems and more accurate time-to-failure predictions will reduce the risk of safety-related system failures and decrease costly inspection routines as well as premature component replacements by using a risk-based, maintenance optimization technique. This development is applicable to civilian aviation applications (passenger aircraft, cargo transports, business jets, private aircraft, etc.). The developed approach and design products could be adapted for a variety of other commercial applications, including: land and marine propulsion systems, industrial actuation systems, fluid power transmission, robotic applications, weapon systems, and air vehicles operating in sustained supersonic cruise.