Lone Star Analysis - CAD/PAD Digital Twin

Naval aviation continues to experience issues with Cartridge Activated Device/ Propellant Activated Device (CAD/PAD) shortages, obsolescence, lot failures, Diminishing Manufacturing Sources and Material Shortages (DMSMS) and production and shipping delays. Reliability Centered Maintenance (RCM) has proven inefficient for effectively managing the service life of the estimated 2M+ CAD/PAD assets in the existing inventory. Because no “as installed” health monitoring capability currently exists to indicate performance/useful life, an estimated 70,000 CAD/PAD components are replaced annually to increase the likelihood that these critical safety items will be effective when needed by aircrew and to avoid inadvertent actuations. Understandably, conservative service life limits are established to address substantial uncertainty. A bi product of the conservatism is that many of the components removed prior to expiration are done so with significant effective useful life remaining. The vision of the SBIR proposal is to establish a non-intrusive system of automated analysis tools (digital twins) that deliver near real-time performance/useful life projections (by device serial number) and associated maintenance intervention metrics for the entire CAD/PAD inventory. The Direct to Phase II effort leverages some preliminary F/A-18 ejection seat work already conducted by Lone Star Analysis and focuses on operationalizing the capability through delivery of a secure, web based, enhanced Condition Based Maintenance (CBM) capability that is accessible via the Navy’s network and is authorized to connect to authoritative Government data sources as required to monitor and predict CAD/PAD service life and performance. The tools developed will facilitate service life adjustment decisions and support optimized inventory management. The following research and development questions will be addressed: - Can a CAD/PAD digital twin be automated that provides accurate measurements and predictions of remaining useful life? - Is the current RCM approach to removing and replacing target CAD/PADs on established service life timelines impacting safety and/or readiness? - Can an automated CAD/PAD digital twin be achieved without adding additional sensors to the aircraft? - How is a CAD/PAD digital twin most effectively integrated with Government authoritative databases? - What protections are required to ensure the web-based digital twins are safe from cyber threats and are authorized to interface with the Government network of record? - How will the Fleet most effectively employ the CAD/PAD digital twin technology to maximize cost avoidances, improve readiness and eliminate unnecessary risk exposure?