A Generic Prognostics Software Module for Characterizing Failure Progression in Gears

Impact Technologies, in cooperation with AERA and FractureAnalysis Consultants, propose the development and implementationof generic gear prognostics software tool set and an associatedset of testing/verification tasks that will provide comprehensivegear prognostics for helicopter drive trains. The proposedprognostic software will integrate advanced failure modemodeling, failure progression rate features, inspection data, andavailable experience bases, to enable the predictive part ofprognostics. The Phase II program will consist of two primarytechnical paths. The first path is related to the development ofa set of software tools that can be utilized to develop a genericgear prognostics module for any critical helicopter drive trainapplication. This development will result in a commercial set ofsoftware modules that OEM's and end-users can use to develop gearprognostic modules for application into existing HUMS boxescurrently on-board military helicopters. The second aspect ofthis proposed program focuses on the testing and verification ofthe gear prognostics module for the CH-60 IGB. Follow-on seededfault testing as well as more fundamental wear and crackinitiation testing is planned to support the development of thesoftware modules. The generic gear prognostics tools to be developed under this program will contain many elements that can be transitioned to a broad range of Naval and other commercial and military applications. The real-time capability of thisprognostic module will make it capable of being integrated within the current HUMS framework currently on-board military helicopters. More accurate time-to-failure predictions are expected to reduce costly inspection routines and premature componentreplacements by using a risk-based, maintenance optimization technique. Commercial applications for the gear prognostics tools can be realized on many turbomachinery applications including commercial aviation engines, electric power generators, industrialdrive systems, and critical pumps and compressors.