Impact Technologies, LLC Some Recent Developments

www.impact-tek.com © 2008, Impact Technologies, LLC – All Rights Reserved 1

Impact Technologies, LLC Some Recent Developments

Carl Byington, P.E.Principal and Director of Systems

Engineering

Impact Technologies, [email protected]

585-627-1926

mailto:[email protected]

© 2008, Impact Technologies, LLC – All Rights Reservedwww.impact-tek.com 2

What We DoDevelop and field sensors, systems, and software that monitor, detect, isolate, predict, adapt control, and plan Provide services to our customer to reduce risk, increase safety, improve readiness, and minimize ownership costs


Some new stuff we have been working on….


Integrated Vehicle Health Monitoring Solutions


Drive trainMain gearbox

Tailrotor gearbox

Engine Vibration

Engine Performance

Electromechanical Actuators

Rotor Balancing

Demonstration of Generation 1 IVHM system


Web-Enabled Fleet Access Concept


Potential applications

General AtomicsMQ-1C Sky Warrior

MQ-1 Predator

MQ-9 Reaper

Unmanned doesn’t mean just aerial vehicles!

Northrop GrummanRQ-8 Fire Scout

RQ-4 Global Hawk

Lockheed MartinMULE

Navy SPAWARSpartan Scout


Vibration-Based PHM Solutions

Extensive Successful Field Application Experience• Aircraft Engine OEM Test Cell • Engine OEM Onboard PHM

• Bearing and Power Transmission Component OEM• Navy and Army Helicopter Platforms

• Various DoD and Industrial Applications

ImpactEnergy™

Bearing Module

GearMod™

Gear Module

GearMod™ Shaft

Shaft Module

Firstcheck™

Sensor Module


In-line Lubricant Quality Interrogation Using Smart Oil Sensor™

Multisensor fluid quality monitorBroadband Impedance Spectroscopy, RH, Temperature measurements

Uses patented broadband measurement technique

Measure more fluid parameters => trend more fluid contaminantsMuch faster than traditional EIS measurementsUS Patent Number 7,239,155

Onboard processingImpedance and feature calculationsDiagnostic and prognostic algorithms

CAN, RS232, and other communications interfacesAdapting a version for aircraft applications


Structural Corrosion PHM

Leverage sensing and embedded systems expertise to create an ultra-low power sensing device for use

in detecting corrosive environments

Features• Real-time, In-situ Corrosivity Monitor

• Multi-Sensor Design• Low Power

• Miniature, Light Weight• Embedded Processing

• Wired / Wireless Communication


Advancing Non-destructive Inspection for Composites

Disbond

Repair

F-15 Stabilator Section


mLIFE™ – Rocket Motor Life Prediction Software


Wireless Monitoring on Landing Systems

Integration of multiple sensing and wireless transmission to remote processing display


Helicopter Component Prognostics Improvement Program

δ1

P’

Time Present MTTF PredictionX%

Confid.

Pf

X% Precision

Hazard Lines

Hazard Lines

1.0

Raw data

Data-drivenCI’s

Fusion

Physics-of-failure

mechanisms

Model-basedCI’s

Damage progression mechanisms

Diagnostics:current health

state

Prognostics:future health

state

Usage /operating conditions

0 0.5 1 1.5 2 2.5 3 3.5

x 104

-1

0

1x 10

4 Simulated Vibration Signal

0 0.5 1 1.5 2 2.5 3 3.5

x 104

-5

0

5x 10

4 TSA of Vibration

200 300 400 500 600 700 800 9000

2

4

6

8x 10

7 FFT of TSA

1100 1110 1120 1130 1140 1150 1160 1170 11800

1

2

3x 10

7 Close-up view of Fifth Mesh Harmonic

0 0.5 1 1.5 2 2.5 3 3.5

x 104

-1

0

1x 10

4 Simulated Vibration Signal

0 0.5 1 1.5 2 2.5 3 3.5

x 104

-5

0

5x 10

4 TSA of Vibration

200 300 400 500 600 700 800 9000

2

4

6

8x 10

7 FFT of TSA

1100 1110 1120 1130 1140 1150 1160 1170 11800

1

2

3x 10

7 Close-up view of Fifth Mesh HarmonicComponents

Sensors

VMEP/HUMS

Experience(FMECA,

RCM)

Front bearing w/debris


Improving Strain Gauge Calibration Factor Assessment

Replace time consuming static loading or special

flight tests to calibrate strain

sensors.

Static Load Test


Force and Strain Measurementsfor Input Excitation and Structural Response

Strain GagesBonded-foil resistance strain gages: small wire or foil grid on a thin polymer substrate

Piezoresistive (semiconductor) bonded to structure or deposited as a thin-film

Load Cellattached to a shaker or integrated to an impact hammer

Data Acquisition using NI equipment & LabVIEW

Strain Gage

ShakerLoad Cell


Concept Verification TestsPeriodic Excitation Test

Tabulate excitation frequency, input force, strain output, CF, and deviation of CF

(test mode 1 configuration and periodic excitation on location 1)

Average = 1.062 compare to 1.07 for Static


NASA NRA EMA Test Stand and Software Package


Virtual Test Environment (VTE)

Consists of components that enable actuator testing

ControllerDriveLoading MechanismSensorsUser Interface

Dynamically links test and load EMAsStandardized controller, drive, & sensors blocks


Initial PHM Results Preliminary fault assessment routines have been developedImplements reduced order (static) actuator model and automated optimization routine to obtain model parameters that minimize errorFull, dynamic model used to simulate ‘actual’ system responseVirtual Test Environment used to simulate 3 EMA faults ID’d from PHM Design analysis

Motor bearing wear/lubrication degradation (friction increases)Motor winding shortPosition sensor fault


3 days of intensive PHM experiences at annual workshop in Miami, FLAttended by government and industry; developers and end users Training and networking opportunity

Impact Technologies, LLC Some Recent Developments

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