Aircraft Prognostics Health System Using Usage-Based Life Assessment
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Solution Overview
Problem
Current aircraft reliability models tend to err on the side of caution, leading to premature replacement of components and increased operating costs, while relying solely on measured usage may result in certification issues due to potential underestimation of remaining useful life.
Innovation Solution
Developing a system that calculates the remaining useful life of aircraft components based on actual usage data, using probability-of-failure models and usage history to credit back life to components, thereby balancing economic and safety concerns and satisfying certification requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conservative reliability models are used to assess component life, then safety and reliability are improved, but component replacement occurs prematurely increasing operating costs
Solution Approach 1:
The system changes the parameter of life assessment from conservative fixed models to usage-based dynamic calculations. By incorporating actual usage data (flight hours, cycles, intensity) into the reliability model, the system adapts the assessment parameters to reflect real component degradation patterns, allowing more accurate remaining useful life determination that balances safety with cost-effectiveness
Solution Approach 2:
The system implements feedback by continuously monitoring actual component usage and comparing it against predicted usage patterns. This feedback loop allows the system to update reliability assessments in real-time, adjusting replacement recommendations based on actual degradation observed rather than relying solely on conservative predetermined models, thereby reducing premature replacements while maintaining safety
2Loss of energy
If usage-based life calculations are implemented, then operating costs are reduced by avoiding premature replacement, but certification requirements may not be satisfied due to potential underestimation of remaining useful life
Solution Approach 1:
The system applies partial action by implementing usage-based calculations for routine operational assessments while maintaining conservative certification thresholds for official certification compliance. For certification purposes, the system can apply more conservative estimates to ensure compliance, while allowing usage-based optimized assessments for operational decision-making, thus satisfying both cost reduction goals and certification requirements
Solution Approach 2:
The system uses dynamics by making the reliability assessment approach adaptable based on the context. The same component data can be analyzed using different methods depending on whether the goal is operational cost optimization or certification compliance. This dynamic selection of assessment methodology allows the system to satisfy both conservative certification requirements and usage-based cost-effectiveness goals
Data Source
AI summary
According to one example embodiment, a method of assessing use of an aircraft component installed on an aircraft includes receiving, from one or more sensors installed on the aircraft, one or more measurements representative of at least one load applied against the aircraft component; selecting at least one usage model from a plurality of usage models, each usage model of the plurality of usage models relating aircraft loads with received sensor data; determining at least one load value based on the selected at least one usage model and the received one or more measurements; and calculating, based on the determined at least one load value, an amount of change in probability of failure caused by application of the at least one load against the aircraft component.