Incipient Fault-to-Failure Progression Models and Software for Drive Train Clutch Systems

Impact Technologies (Impact), in collaboration with Rolls-Royce (RR), proposes to further develop and demonstrate a prognostic modeling and data processing paradigm for use with drive train components such as gears, bearings, shafts and clutches. Drive train and clutch systems on modern weapons platforms are highly dynamic and have the potential for high load densities due to compact packaging and minimal design margins. There is an extensive amount of functional interaction and dependency between the propulsion and drive systems, which complicates the tracking of faults as they progress to the point of compromising function (failure). Moreover, there exists uncertainty in modeled conditions, properties and measured fault indicators. In order to develop a truly predictive capability under these conditions, Impact proposes to mature its Phase I developed system models, wear and fatigue failure mode progression (prognostic) algorithms, machinery vibration analysis techniques and advanced knowledge fusion methods within a probabilistic framework and apply it to the major driveline components of the Joint Strike Fighter LiftFanT system. The algorithms will account for specific conditions and mechanical uncertainties to determine the existence of faults and, whenever possible with sufficient historical trending, the remaining useful life of the critical, life-limited LiftFanT components. Phase II will focus on development, verification and a transition plan with consideration to the Rolls-Royce drive train development program and its Prognostic and Health Management (PHM) needs. As part of this effort, Impact proposes to provide near real-time monitoring of the JSF LiftFanT test cell (Rig 157) located at Rolls Royce's Indianapolis facility. This monitoring capability will employ advanced vibration techniques to monitor the health and detect incipient faults present in LiftFanT gears and bearings. Upon completion of this proposed Phase II effort, Impact will validate the developed software/hardware package on the available operational data and demonstrate its capabilities using a customized graphical interface. Impact will also evaluate the use of such algorithms for onboard PHM through further enhancements.