Very High Frequency (VHF) Monitoring System for Engine Accessories Health Management

Impact Technologies, in collaboration with Rolls-Royce, proposes to develop and demonstrate an integrated approach to predicting remaining life of gas turbine engine accessories. The approach features novel very high frequency (VHF) vibration diagnostics, specifically customized for detection of common engine accessory (including fuel pumps, hydraulic pumps, starters, generators, etc.) faults, combined with accurate, adaptive component-specific prognostics. Key innovations include adaptive signal processing approaches that accentuate high frequency vibrations, novel prognostic updating techniques, and prognostic and diagnostic fusion. In Phase I, Impact will determine the optimal techniques for use in VHF component diagnostics. Metrics for technique selection will be based on incipient fault detection capability, diagnostic accuracy, and computational requirements. Multiple techniques may be selected since certain techniques may be better suited for certain component failure modes. The diagnostic and prognostic development will be driven by the understanding of specific component failure modes and Impacts existing domain expertise in PHM technologies. Impact is well positioned to leverage their experience and knowledge of vibration, fatigue analysis, and predictive technology in order to develop a commercializable product for application on a variety of systems. A complete hardware/software solution will also be considered to enable Distributed PHM and maximize commercialization potential. BENEFIT: The proposed program features numerous innovations that will benefit the military and commercial market. These innovations can be used in combination or independently to fulfill current gaps in engine accessory diagnostic technology. For example, the integrated package can be used to provide a comprehensive PHM system that can be used to diagnose all aircraft accessories. Alternatively, component-specific modules can be embedded into the component to create a distributed, smart component product. This system could be packaged for test cell, pass off, or on-board implementation (as computational technology continues to improve). In addition, the proposed embedded system can be sold as a stand alone industrial monitor, because of the widespread use of pumps, motors, and generators in almost every industry. Furthermore, portions of the proposed approach (i.e., algorithms) can be implemented in legacy systems to provide improved detection and fault isolation capability. Ultimately, this program will close the gap between gas turbine engine PHM and accessory PHM technologies. Regardless of the implementation, there are enormous economic (maintenance & logistics), safety, and operational readiness benefits to advancing the state of accessory component health management systems. For example, early fault detection and effective prognostics would reduce unplanned failures, which would in-turn reduce life cycle cost and increase readiness and mission assurance. In addition to military gas turbine engine applications, the proposed work will contain generic elements that can be transitioned to a broad range of other applications without additional sensors. VAHMP could also be implemented in a wide range of civilian/commercial applications, including commercial aircraft, power plants (in particular wind turbines), utilities, transportation, and petrochemical industries where reliability is essential to sustain production and repair times and periods need to be minimized.