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RESTRICTION ON DISCLOSURE AND USE OF DATAThis document includes data which shall not be duplicated, used or disclosed in whole or in part for any

purpose other than to evaluate this proposal and shall not be transferred nor disclosed to a third party without written consent from RSL Electronics LTD. All pages of this document are subject to this restriction

T-HUMS – Total Health & Usage Management System

AH-64 Lead The Fleet (LTF) Summary And A Glimpse At Hermes-450 MT-HUMS

HUMS2005hanan@rsl.co.il

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RSL T-HUMS has been evaluated by the IAF

2002-2004

LTF (lead the fleet) 4 AH-64 aircraft

Daily missions (training & operational) & seeded fault tests

Program track record validated the benefit of safety availability and savings

Similar success was accomplished in UAV

As a result, the following 3 T-HUMS programs exist at the IAF

AH-64A

CH-53

Hermes-450 UAV

Decision to proceed into UH60 T-HUMS & AH64D T-HUMS

OverviewOverview

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Validate T-HUMS ability to address AH-64A “hot issues”

MGB/AGB clutches

VIB-GRBX

APU clutch (new)

SDC (new)

Reduce maintenance flights with focus on RT&B

Demonstrate the potential for CBM / individual maintenances – by matching alerts & facts

Enable decisions - HUMS for the IAF major fleets

Primary LTF ObjectivesPrimary LTF Objectives

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Model-based diagnostics & prognostics

Focus on internal components

Low dependency on former experience / tests

Synergy among all T-HUMS programs

Automatic in-flight diagnostics & decisions in real-time

In-flight advisories

Fast algorithms – true continuous mode

“Safety guards” – Novelty, RMS

Efficient RT&B algorithm

Compact, yet powerful hardware

Small footprint (downloads & analysis)

TT--HUMS Key FeaturesHUMS Key Features

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Interface with existing sensors and 1553 bus

AHAH--64 T64 T--HUMS HUMS –– Top LevelTop Level

Cockpit X 2

NGB R X 1NGB L X 1

Eng R X 2Eng L X 2

Tail Shaft X 2

TGB X 2

IGB X 1

MGB X 8

APU X 1

Ground Station

Integrated flight line system (IFLS)

3 co-processors

Up to 6 GB memory

Classified1

The TThe T--HUMS Information FlowHUMS Information Flow

Flight-line A

Base 1

Detachment B

Fleet Management

Detachment A

Diagnostic Center

Web

Logistic systems

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Pilot DisplaysPilot DisplaysAdvisoriesRT&B Initiated recordingEngine power checks

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IFLS IFLS –– Integrated FlightIntegrated Flight--Line SystemLine System

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Ground Station SpecificationsGround Station Specifications

Functions

Automatic data and diagnostics screening

View alerts

Data analysis

Usage tracking

Manage maintenance

Generate reports

Database management

Configuration management

Web GUI & application

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AH64 TAH64 T--HUMS Track Record SummaryHUMS Track Record SummaryOver 2000 flight hours

~ 550 G Byte data

~ 2000 pointers monitored per each relevant FR

RT&B – average of 1.6 iterations

Initial (current) performance - Detection 94-97%, FA rate 0%

Type of event

Relevat events

Detection counter

Notes

VIBGRBX 15 1 out of the 15 cases, one is a real failure. The rest are false alarms of the VIB-GRBX sys

NGB 7 7SDC 3 2.5 consider SDC sensor upgrade to 30 kHz

MGB 3 3 Detection via failure propagation in the MGB. Improve algorithm for planetary gears

Engines 1 1 FOD

Generator 1 1Total 30 15.5

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Trending Of Vibration FeaturesTrending Of Vibration Features

BL1 2 3 4 1 2 3 4 1 2 3 4

BL BL

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IGB DeteriorationIGB Deterioration

IGB modulation – inlet shaft (5) sidebands

Unbalance of shaft 5 (IGB inlet shaft)

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NGB NGB –– Ball Bearing Ball Bearing –– 11/200311/2003

Confidence level

Inner race Inner race sidebands

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Trends Trends –– Cracked BracketCracked Bracket

Structural vibration change (left chart) picked by the novelty detection algorithm (right chart)

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Crack growth on MGB housingCrack growth on MGB housing

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FOD DetectionFOD Detection

0 50 100 150 200 250 300 350 400-0.05

0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

0.4

02-Feb-200402-Feb-2004

fault probability Nnomfault probability NomdecisionSnapShotNomTrendNomSnapShotNotNomSnapShotNotNomTrendNotNom

905 - Engine Left Accessory - NG shaft

Misalignment code: 127 => Trend dates: from 24-Feb-2003 to 02-Feb-2004

Decision Process

Nominal Trends

Energy growth of NG pointers (unbalance and misalignment) starting from the 1st flight 2-2-2004

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MGB/AGB ClutchMGB/AGB Clutch -- Seeded Fault TestSeeded Fault Test

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FRR and Fatigue

Automatic Regime recognition Enables fatigue tracking

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RT&B

Scale…

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OverOver--Torque MishapTorque Mishap

Fuel System

EnginesFlight Controls

Uncontrolledtouchdown

Over-torque

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Safety

Flight hours

Maintenance

Availability

Operational

TT--HUMS Benefit Analysis & ForecastHUMS Benefit Analysis & Forecast

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AH64 TAH64 T--HUMS Benefits HUMS Benefits –– SafetySafety

Prevention of dual MGB / AGB clutch failure (failure means no hydraulics & no AC power)Prevention of APU clutch failure (failure can cause fire)

Prevention of generator in-flight failurePrevention of SDC in-flight failure (failure can cause fire)

Prevention of NGB in-flight failurePrevention of false VIBGRBX warnings (existing a/c system)Prevention & detection of FOD BDA

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Maintenance flights with a fully qualified crew - handle aircraft emergencies (*)(**)

Clear information on in-flight failures – less room for error at the cockpit

Lower vibration – less physiological stress

Lower workload – power checks, recording…

Mishap analysis = risk reduction

Less maintenance (& ground runs) = less room to make errors = safety

(*) A Team work enables the correct answer in case of in-flight problem(**) Without T-HUMS – a technician is needed instead of front pilot

AH64 TAH64 T--HUMS Benefits HUMS Benefits –– SafetySafety

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Flight Hours Savings Flight Hours Savings Reduction of RT&B maintenance flights (*)

Pilot initiated ~ 90% reductionAfter maintenance ~ 70-50% reductionNight time executable and without a technician

Reduction of engine maintenance flightsHIT & Power checks ~ 80-90% reduction (*)Post FOD replacements ~ 70-90%

Reduction of maintenance flights after scheduled maintenance Planned MGB removals ~ potential increase from 900 to 1800hPlaned pitch housing replacements ~ potential increase from 620 to 1200-1800hFuture expansion of inspection & maintenance intervals ~ potential increase ~ 30-60%

(*) Most resulting maintenance flights will be executed after maintenance activity (such as after I-level inspection or engine removals) and not to initiate maintenance

Lower by~ 90-80%

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OO--Level WorkLevel Work--Load Reduction Load Reduction Reduction tail VIBGRBX ground runs ~ 95%Reduction of tail rotor balancing ground run

Pilot initiated ~ 90% reductionAfter maintenance ~ 50% reduction

Reduction of APU & Engines ground runsFault confirmationTroubleshooting ~ 50-70%

Prevention of :Unneeded removals of dynamic systems ~ 90% reductionUnneeded ground runs due to tail vibration (VIBGRBX)

FOD related engine removals ~ reduction of 70-90%Troubleshooting time (drive train, rotors, engines, fuel system) ~ direct effort cut by ~ 70-90%

Lower by~ 90-70%

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OO--Level BenefitsLevel Benefits

Minimal dependency on experts including for RT&B flights

No need to install instrumentation (GSE) for testing

Less scheduled maintenance – inspections & removals

Less non-required maintenance – parts & labor

Less AOG

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DD--Level Maintenance Savings Level Maintenance Savings Prevention of FOD engine repairs ~ reduction of 70-90%Gearboxes overhaul cost of replaced parts - reduction of

All “chips initiated” ~ 50% (due to on-time removals and smaller damage)Replacements IAW diagnostic report

Extending the overhaul intervalsPlanned MGB removals ~ potential increase from 700 to 1800hPlaned pitch housing replacements ~ potential increase from 620 to 1200-1800hFuture expansion of inspection & maintenance intervals ~ potential increase ~ 30-60%

ROM Saving~ 50%

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Potential to:

Reduce inspection tasks - shorter

Increase intervals ~ (20-100% - case sensitive)

Lower overhaul cost

Lower cost – labor & parts

AH64 TAH64 T--HUMS Benefits HUMS Benefits –– Inspections & Scheduled Inspections & Scheduled Maintenance Maintenance –– All EchelonsAll Echelons

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Deployments

Smart selection of deployed helicopters

Less GSE needed – smaller logistic foot-print

Special missions

Correct selection of best helicopters for the mission

Deployments & Special MissionsDeployments & Special Missions

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Crisis

A new failure mode found

The fleet is grounded for inspection & tests

Significant management attention

T-HUMS enables

Fast screening

Risk planning and reduction

Quick recovery to normal operation

Crises HandlingCrises Handling

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Additional helicopters daily at the flight-line

Fleet availability – 10-15% higher

Faster recovery from crises

Operational ReadinessOperational Readiness

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Squadron Commander POVSquadron Commander POVLess maintenance flightsLess mission aborts (ground & air)Higher mission reliabilityLess workload on aircrewMore daily available aircraftLess interruption to training and operationsLess deployment overheadsNight time executable maintenance flightsDebriefing capability:

Tactical debriefingFlight quality & aircraft handling (supporting MFOQA)Mishaps analysis

Simpler squadron managementMore effective squadron operationBetter training & readiness

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Fleet Manager POVFleet Manager POVMore successful missions with less aircraftHigher readiness level and availability of the fleetMore effective fleetLower flight hour costLess management overheads

Lower budgetBetter force build up

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SummarySummaryT-HUMS – A different type of HUMS

The AH64 T-HUMS LTF Program had met its objectives

T-HUMS works

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Glimpse at Glimpse at Hermes-450 MT-HUMS

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Airborne Segment

MTMT--HUMS Data FlowHUMS Data Flow

Ground Segment

Ground control Stations

Integrated Flight-Line System

(*) Implemented without the OEM

Ground Stations

Insurance policyfor low-intensity

high-demand mission

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Altitude (up to 15KAltitude (up to 15K’’) & Vibrations) & Vibrations

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Engine ParametersEngine Parameters--Based DiagnosticsBased Diagnostics

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Ignition Circuit #1 Failure Ignition Circuit #1 Failure

Ignition current #1 (RMS) drops to zero during climb

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SummarySummaryProven MT-HUMS/T-HUMS technology COTS MT-HUMSValidated MT-HUMS performance & benefits MT-HUMS

Insurance policy for UAVs – platform, payload, mission & operationIncrease MTBL and MTBUSV

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Contact RSLContact RSL

www.rsl.co.ilhanan@rsl.co.il

Artificial Intelligence

Vibration Analysis

Electronics Hardware

Knowledge of Aerospace engines

Software applications & GUI