DOCSLIB.ORG

Design and Development of Prognostic and Health Management System for fly-By-Wire Primary flight Control Electrohydraulic Servoactuators

Total Page：16

File Type：pdf, Size：1020Kb

Download full-text PDF Read full-text
Design and Development of Prognostic and Health Management System for fly-By-Wire Primary flight Control Electrohydraulic Servoactuators Politecnico di Torino Department of Mechanical and Aerospace Engineering Ph.D. degree in Mechanical Engineering Design and development of prognostic and health management system for fly-by-wire primary flight control electrohydraulic servoactuators Candidate: Andrea Mornacchi Thesis advisor: Prof. G. Jacazio Thesis submitted in 2016 Allegato n.6 COMMISSIONE GIUDICATRICE ll dott. Andrea MORNACCHI ha discusso in data ha discusso in data 29 aprile 2016 presso il Dipartimento di lngegneria Meccanica e Aerospaziale del Politecnico di Torino la tesidi Dottorato avente il seguente titolo: Design and development of prognostic and health management system for fly-by- wire primary fly control electrohydraulic servoactuators Le ricerche oggetto della tesi sono eccellente livello. Le metodologie appaiono molto buone. I risultati sono interessanti ed analizzati con elevato senso critico. Nel colloquio il candidato dimostra ottima conoscenza delle problematiche trattate. La Commissione unanime giudica estremamente positivo il lavoro svolto e propone che al dott. Andrea MORNAGCH| venga conferito il titolo di Dottore di Ricerca Data, 29 aprile 2016 Prof. Carlo Ferraresi (Presidente) Prof. Stefano Beretta (Componente) Prof. Enrico Ravina (Segretario) iii Prediction is very difficult, especially if it’s about the future. Nils Bohr Abstract Electro-Hydraulic Servo Actuators (EHSA) is the principal technology used for primary flight control in new aircrafts and legacy platforms. The devel- opment of Prognostic and Health Management technologies and their appli- cation to EHSA systems is of great interest in both the aerospace industry and the air fleet operators. This Ph.D. thesis is the results of research activity focused on the devel- opment of a PHM system for servovalve of fly-by-wire primary flight EHSA. One of the key features of the research is the implementation of a PHM sys- tem without the addition of new sensors, taking advantage of sensing and information already available. This choice allows extending the PHM capa- bility to the EHSAs of legacy platforms and not only to new aircrafts. The enabling technologies borrow from the area of Bayesian estimation theory and specifically particle filtering and the information acquired from EHSA during pre-flight check is processed by appropriate algorithms in order to obtain relevant features, detect the degradation and estimate the Remaining Useful Life (RUL). The results are evaluated through appropriate metrics in order to assess the performance and effectiveness of the implemented PHM system. The major objective of this contribution is to develop an innovative fault diagnosis and failure prognosis framework for critical aircraft components that integrates effectively mathematically rigorous and validated signal pro- cessing, feature extraction, diagnostic and prognostic algorithms with novel uncertainty representation and management tools in a platform that is com- putationally efficient and ready to be transitioned on-board an aircraft. Keywords: Prognostics and Health Management (PHM), Condition Based Maintenance (CBM), fly-by-wire primary flight control, ElectroHydraulic ServoValve (EHSV) vii Contents 1 Introduction to PHM 1 1.1 Historical perspective . .2 1.2 Prognostics and health management . .4 1.3 Automatic diagnostic . .7 1.3.1 Requirements and performance metrics . .8 1.3.2 Alarm bounds approach . 10 1.3.3 Data-based approach . 11 1.3.4 Data-driven approach . 13 1.3.5 Model-based approach . 15 1.4 Prediction of residual useful life . 18 1.4.1 Requirements and performance metrics . 19 1.4.2 Model-based approach . 21 1.4.3 Probability-based approach . 23 1.4.4 Data-driven approach . 24 1.5 PHM for flight control actuators . 25 2 Reference servoactuator 29 2.1 Flight control system overview . 30 2.1.1 Primary flight control systems . 32 2.1.2 High lift control systems . 33 2.2 Boeing 777 flaperon EHSAs . 34 2.2.1 Hydraulic manifold . 35 2.2.2 ElectroHydraulic Servovalve . 37 3 Servovalve degradations 39 3.1 Selected degradations . 40 3.2 Reduction magnetomotive force . 41 3.3 Contamination of nozzles and filter . 42 3.4 Yield feedback spring . 43 3.5 Feedback spring backlash . 44 3.6 Friction force variation . 45 ix x Contents 3.7 Radial gap increase . 45 4 Mathematical model 47 4.1 Model structure . 48 4.2 Actuator . 50 4.2.1 Coulomb friction . 53 4.2.2 Actuator stoke limits . 56 4.3 Servovalve . 57 4.3.1 Discharge coefficient . 70 4.4 Surface . 71 4.5 Controller . 72 4.6 Position transducer . 74 4.7 Aerodynamic force . 74 4.8 Oil Properties . 75 5 Mathematical model validation 79 5.1 Test Bench . 80 5.2 Open loop tests . 82 5.3 Close loop tests . 84 5.4 Validation results . 85 6 PHM strategy 87 6.1 Available information . 88 6.2 Adopted strategy . 89 6.2.1 Implemented command . 91 6.3 PHM algorithm . 94 6.4 Operative scenario . 96 7 Features extraction 99 7.1 Extracted features . 100 7.1.1 Position features . 101 7.1.2 Current features . 103 7.2 Influence of operative conditions . 105 7.2.1 Fluid parameters . 106 7.2.2 Noise and environmental disturbances . 117 7.3 Influence of manufacturing tolerances . 120 7.4 Features evaluation . 123 7.4.1 Reduction magnetomotive force . 124 7.4.2 Contamination of nozzles . 126 7.4.3 Variation of the stiffness of the feedback spring . 130 Contents xi 7.4.4 Increase of the backlash between spool and feedback spring . 132 7.4.5 Variation of the friction force between spool and sleeve 133 7.4.6 Increase of the radial gap . 136 7.4.7 Summary . 138 8 Fault diagnosis 141 8.1 Fault diagnosis requirements . 142 8.2 Fault diagnosis techniques . 143 8.3 Alarm bounds approach . 144 8.3.1 Results overview . 150 8.3.2 Summary . 163 8.4 Probability Density Function approach . 164 8.4.1 Detection with PDF from real-data . 165 8.4.2 Detection with PDF from particle filter . 167 8.4.3 Result overview . 170 8.4.4 Summary . 181 8.5 Summary . 184 9 Fault classification 187 9.1 Classification technique . 187 9.2 Classification of the first degradation . 189 9.3 Classification of additional degradations . 193 9.4 Summary . 197 10 Residual useful life estimation 199 10.1 RUL estimation technique . 200 10.2 Degradation model fitting . 201 10.3 RUL estimation . 203 10.4 Results overview . 206 10.5 Evaluation . 209 10.6 Summary . 213 11 Conclusion 215 11.1 Summary . 215 11.2 Future developments . 217 A Random pattern generator 219 Bibliography 223 List of Figures 1.1 An integrate PHM approach . .5 1.2 PHM cycle . .5 1.3 ISO 13374-1 processing model . .8 1.4 Alarm bounds . 10 1.5 Neural network example . 12 1.6 Neural network decision regions . 13 1.7 Detection using PDF comparison . 15 1.8 Prognosis technical approaches . 19 1.9 Prognosis result example . 20 1.10 PHM system proposed by Byington et al . 26 2.1 Position of the three principal axes . 30 2.2 The fly-by wire EHSA and its interactions . 32 2.3 Layout of the primary controls of Boeing 777 ......... 33 2.4 Boeing 777 flaperon . 34 2.5 Flaperon scheme . 35 2.6 Flaperon manifold scheme . 36 2.7 EHSV scheme . 37 3.1 Selected degradations . 41 3.2 Nozzle clogging . 43 3.3 Yield feedback spring . 43 3.4 Feedback spring backlash . 44 3.5 Friction force variation . 45 3.6 Radial gap increase . 46 4.1 Mathematical model layers . 49 4.2 EHSA model scheme . 50 4.3 Actuator lumped model . 50 4.4 Rod free body diagram . 52 4.5 Sleeve free body diagram . 53 xiii xiv List of Figures 4.6 Actuator seals . 54 4.7 Coulomb friction . 56 4.8 Stroke limits - saturation signal . 56 4.9 Stroke limits - subsystem . 57 4.10 Model EHSV scheme . 58 4.11 Torque motor equivalent circuit . 58 4.12 Distribution of air-gaps . 61 4.13 Flapper free body diagram . 65 4.14 Spool free body diagram ..
Load more

Recommended publications
  • Series 505G2 Silentflo™ Hydraulic Power Unit
    Series 505G2 SilentFlo™ Hydraulic Power Unit Model 505G2.07, Model 505G2.11 100-227-350 C ©2015 MTS Systems Corporation. All rights reserved. MTS Trademark Information MTS, be certain., Bionix, ElastomerExpress, FlatTrac, FlexTest, Just In Case, LevelPlus, MTS Criterion, MTS EM Extend, MTS Insight, MTS Landmark, RPC, ServoSensor, SWIFT, Temposonics, TestWare, TestWorks are registered trademarks of MTS Systems Corporation within the United States. Acumen, AdapTrac, Advantage, Aero ST, Aero-90, AeroPro, Criterion, CRPC, Echo, First Road, Flat- Trac, Landmark, MAST, MicroProfiler, MPT, MTS Acumen, MTS Echo, MTS Fundamentals, MTS TestSuite, ReNew, SilentFlo, TempoGuard, TestLine, Tytron, Virtual Test Lab, and VTL are trademarks of MTS Systems Corporation within the United States. These trademarks may be registered in other countries. All other trademarks are the property of their respective holders. Proprietary Software Software use and license is governed by MTS’s End User License Agreement which defines all rights retained by MTS and granted to the End User. All Software is proprietary, confidential, and owned by MTS Systems Corporation and cannot be copied, reproduced, disassembled, decompiled, reverse engineered, or distributed without express written consent of MTS. Software Verification and Validation MTS software is developed using established quality practices in accordance with the requirements detailed in the ISO 9001 standards. Because MTS-authored software is delivered in binary format, it is not user accessible. This software will not change over time. Many releases are written to be backwards compatible, creating another form of verification. The status and validity of MTS’s operating software is also checked during system verification and routine calibration of MTS hardware.
    [Show full text]
  • DCA Brochure June 19 V5.0.Indd
    Hydrastore Stockists & partners: hydraulic pumps, valves, motors, actuators, electronics and radio control solutions Fluid PowerDCA Partnership DCA A single UK source for worldwide Fluid Power Partnership hydraulic knowledge, manufacture, Related Valley supply andHydrastore technical supportHydraulic Systems & Components Fluid Power Hydraulics Manufacturers of Manufacturers integrated hydraulic manifolds, of standard and specialist cartridge valves specialist bespoke and mini power units hydraulic cylinders RelatedHydraulic Controls & Power Units specialist cartridge valves + mini power units ValleySpecialist Manufacturers Hydraulics of Hydraulic Cylinders The DCA sales structure We design and manufacture complete systems for all applications and sectors. DCA acts as a central source for sales and technical Established over 50 years assistance, supplying dependable and cost effective ago, DCA has a depth of hydraulic application hydraulic components, systems and electronic experience rivalled by few. solutions through our partner companies. To provide the ideal solution, understanding Our structure is both unique and effective. It provides the application and its a nationally based sales team, an extensive and cost function is critical. Logistics Automotive Process machinery effective equipment portfolio, an accessible engineering At DCA we pride resource, hydraulic design capability and technical ourselves in our application knowledge support. It’s the proven combination and provides our and the associated customers with the total service
    [Show full text]
  • Modeling of the Manifold Configuration for Maximum Efficiency in a Hydraulic Machine
    International Journal of Fluid Machinery and Systems DOI: http://dx.doi.org/10.5293/IJFMS.2019.13.1.136 Vol. 13, No. 1, January-March 2020 ISSN (Online): 1882-9554 Original Paper Modeling of the Manifold Configuration for Maximum Efficiency in a Hydraulic Machine Kesar M Kothari 1, R.Udayakumar1, Ram Karthikeyan1, Vishweshwar S1and Nikitha Raj2 1Department of Mechanical Engineering, Bits Pilani Dubai Campus Dubai, United Arab Emirates, [email protected], [email protected], [email protected], [email protected] 2Department of Electrical & Electronics Engineering, Bits Pilani Dubai Campus Dubai, United Arab Emirates, [email protected] Abstract Hydraulic manifolds are metal cuboids machined to realize the compact circuit layout within them. They are introduced in the hydraulic machines to fit the large and complex hydraulic system layouts in narrow spaces available in the machines. Therefore, designing of the manifold in fact is more oriented towards achieving minimum size and weight. But the use of manifold, may introduce high pressure losses in the system. Efficiency of the system decreases and temperature of the fluid increases with pressure drop. This present research work focuses on understanding the pressure losses in the most common channel connections used in the manifold to realize the hydraulic circuit and to understand the efficiency of the manifold at different flow values. To achieve these objectives, a real-time case study is considered, where a manifold for a cable pulling winch machine is modified to reduce the pressure drop and increase the efficiency of the machine. Simple channel models are considered and analyzed using semi empirical equations available in the literature and are compared with results obtained from Computational Fluid Dynamics (CFD) analysis.
    [Show full text]
  • Principles of Small-Scale Hydraulic Systems for Human Assistive Machines
    Principles of Small-Scale Hydraulic Systems for Human Assistive Machines A Dissertation SUBMITTED TO THE FACULITY OF UNIVERSITY OF MINNESOTA BY Brett Cullen Neubauer IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE DEGREE OF DOCTOR OF PHILOSOPHY Advisor: William K. Durfee, PhD March 2017 © Brett C. Neubauer 2017 Acknowledgements I would like to thank my parents Paul and Linda Neubauer in the continuous support of my academic pursuits. It is their guidance from a young age that led me to pursue my aspirations in education and of knowledge. I would also like to give thanks to my adviser Professor William Durfee at the University of Minnesota for sharing his expertise and guidance during my graduate education. There are several individuals that need to be acknowledged for their efforts in this research. Jonathan Nath is a mechanical engineering student completing his master degree at the University of Minnesota, and he provided assistance in designing and building the electrohydraulic power supply for the hydraulic ankle-foot orthosis. He has also provided assistance and expertise in the design and construction of the ankle actuator assemblies of the pediatric hydraulic ankle-foot orthosis. Sangyoon Lee, a PhD candidate in the mechanical engineering program at the University of Minnesota, assisted in developing the axial piston pump performance model. Dr. Andre Ries is a PhD graduate working at Gillette Children’s Hospital in St. Paul, MN, and he assisted with the collection of AFO stiffness data using the BRUCE measurement system. Dr. Ries also provided gait data collected with 3D motion capture for patients with cerebral palsy.
    [Show full text]
  • 350 Autoform Cnc Forming Center
    OPERATION, SAFETY AND MAINTENANCE MANUAL 90 – 350 AUTOFORM CNC FORMING CENTER VME II CONTROL FOR MACHINES BUILT BEFORE OCTOBER, 1992 C I N C I N N A T I I N C O R P O R A T E D C I N C I N N A T I , O H I O 4 5 2 1 1 EM-444 (N-09/99) COPYRIGHT 1999 CINCINNATI INCORPORATED AUTOFORM® CNC FORMING CENTER CONTENTS INTRODUCTION SECTION 1 IDENTIFICATION SECTION 2 INSTALLATION UNLOADING 2-1 LIFTING AND MOVING 2-1 FOUNDATION 2-1 ERECTION 2-2 ELECTRICAL ENCLOSURE INSTALLATION 2-3 CLEANING 2-3 LEVELING 2-3 GAGE INSTALLATION 2-4 HYDRAULIC RESERVOIR 2-5 LUBRICATION 2-5 ELECTRICAL CONNECTION 2-5 SECTION 3 SAFETY SAFETY RECOMMENDATIONS 3-1 SAFE OPERATION 3-1 OPERATING RULES 3-2 INSTALLING / REMOVING TOOLING GUIDELINES 3-3 SAFETY SIGNS 3-3 SAFETY GUIDELINES 3-5 SAFETY MAINTENANCE CHECK 3-5 SECTION 4 SPECIFICATIONS PERFORMANCE AND RATINGS 4-1 SPECIFICATIONS CHART 4-2 PRINCIPLE OF OPERATION 4-2 DEFINITION OF TERMS 4-2 CAPACITIES 4-4 PUNCHING CAPACITY 4-4 STRIPPING CAPACITY 4-4 ECCENTRIC LOAD CAPACITY (F-B) 4-4 OFF-CENTER LOAD CAPACITY (L-R) 4-5 SECTION 5 SET-UP & USE TOOL INSTALLATION - SET-UP MENU 5-1 TYPES OF DIES 5-1 TOP OF DIE CALIBRATION FOR UNMEASURED TOOLS 5-5 GAGING - STANDARD BACKGAGES 5-5 CAPACITY 5-5 SELECT GAGE SURFACE 5-6 ADJUST GAGE FINGER POSITION 5-7 GAGE BAR CALIBRATION 5-8 PROGRAM GAGE POSITION(S) 5-8 GAGE FINGER ADJUSTMENT 5-8 WORK SUPPORTS 5-9 OPERATING TECHNIQUES 5-9 TOOLING AND SET-UP 5-9 RUNNING 5-10 SPEED CHANGE/FORMING SPEED 5-10 GAGES 5-10 REMOVING TOOLING 5-10 EM-444 (N-09/99) SECTION 6 MACHINE CONTROLS MACHINE CONTROLS STATION
    [Show full text]