On-Component Maintenance Tracking for Accurate Aircraft RUL
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current aircraft component maintenance practices are inefficient due to reliance on simple usage metrics, manual data entry, lack of accurate record tracking, and inability to identify errors, leading to inaccurate damage assessment and life prediction, as well as accessibility issues with records.
Innovation Solution
A system with a configuration/maintenance module (CMM) and remaining useful life (RUL) module, integrated with sensors and a central maintenance computer, that automatically tracks and updates usage and maintenance data, identifies discrepancies, and provides accurate RUL values based on configuration, usage, and environmental data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual creation and maintenance of historical service records is used, then personnel can track component information, but the process is time-consuming and prone to errors
Solution Approach 1:
The CMM enables self-service by automatically tracking and recording component usage data, environmental conditions, and maintenance history without requiring manual data entry. The system autonomously monitors parameters such as flight hours, cycles, and operational conditions, storing this information in its memory, thereby eliminating the need for personnel to manually create and maintain records while ensuring accurate tracking.
Solution Approach 2:
The patent replaces the manual mechanical process of record-keeping with an automated electronic system. The CMM uses electronic sensors and memory to automatically capture and store component data, substituting the manual paper-based or electronic database entry process with an automated electronic monitoring and recording system that continuously tracks component status and usage.
2Ease of operation
If simple usage metrics are used for maintenance tracking, then the system is easy to operate, but damage assessment and life prediction are inaccurate
Solution Approach 1:
The CMM transitions from tracking simple usage metrics to monitoring multiple operational parameters simultaneously. The system captures comprehensive data including flight hours, flight cycles, environmental conditions (temperature, humidity, pressure), and operational loads. By changing from a single parameter (simple usage metrics) to multiple parameters (comprehensive operational data), the system maintains ease of operation while significantly improving the accuracy of damage assessment and remaining useful life prediction.
3Loss of information
If centralized electronic records are used, then data can be stored and accessed, but accessibility issues occur in remote locations
Solution Approach 1:
The patent segments the centralized record-keeping system by placing a CMM with full maintenance records and usage data directly on each component. This segmentation allows the component to carry its own historical service records, making the information independently accessible without requiring connection to a centralized database. The component's self-contained memory stores all necessary maintenance history, enabling access in remote locations where centralized systems may be unavailable.
4Extent of automation
If on-component tracking with CMM is implemented, then automated tracking and accurate RUL values are achieved, but device complexity increases
Solution Approach 1:
The CMM is designed as a universal, multi-functional device that consolidates multiple capabilities into a single component. It simultaneously performs usage tracking, environmental monitoring, maintenance record storage, RUL calculation, and communication functions. By making the CMM universal and multi-functional, the system achieves high automation without proportionally increasing overall system complexity, as one device handles multiple tasks that would otherwise require separate systems.
Data Source
Figure 1A~1B
Figure 2
Figure 3A
AI summary
One embodiment is a system (300) including a component (301A, 301B) for installation on a vehicle (302) comprising a central maintenance computer ("CMC") (315); a configuration/maintenance module ("CMM") (303A, 303B) associated with the component (301A, 301B) and including memory (305) for storing component information, a sensor (307) for detecting a condition and generating data indicative thereof; a microprocessor (306) for processing the sensor data and updating the component information with the processing results; and a communications interface between the CMM (303A, 303B) and the CMC (315). The system (300) further includes a remaining useful life ("RUL") module (310) associated with the component (301A, 301B) that periodically updates an RUL, the RUL module (310) periodically updating an RUL value for the component (301A, 301B) and communicating the updated RUL value to the CMM (303A, 303B) for storage in the memory (305). The CMC (315) communicates with the CMM (303A, 303B) to update the component information included in the memory (305) based on information input to the CMC (315) by a user or changes in a condition of the vehicle (302).