Aircraft Electrical Power System Diagnostics and Health Management

This proposal leverages GTC's experience in developing diagnostic and prognostic algorithms, Oak Ridge National Laboratory's testing facilities and experience in applying Electrical Signature Analysis to electro-mechanical systems, Innovative Power Solutions experience in developing generators and studying their failure modes, and Boeing’s experience in testing and integrating algorithms into their Integrated Vehicle Health Management system. During Phase I, several key failure modes common for oil and air cooled generators were identified along with their symptoms, existing methods of detection, diagnostic potential and recommended sensors. An architecture for diagnostic / prognostic health management for aircraft electrical power systems was conceptualized and the algorithms prototyped in Matlab. A test plan was developed and vibration, phase current and voltage data was collected at 100 kHz from a P3 generator with the main bearing exposed to lubrication defects (silicon carbide grit). The generator data was analyzed in the time and frequency domains and compared to analysis of Non-high hour and high hour generators. Features were developed to distinguish between generators with healthy and degraded bearings. Also, a diagnostician and virtual sensor were was prototyped to detect winding shorts and determine the degree of winding shorts occurring in a generator from simulation data generated by a Simulink model of a generator with winding shorts. The feasibility of developing and deploying diagnostic/prognostic system for P-3 generators was determined. The primary goal of the proposed Phase II is to design and demonstrate a proof of concept diagnostic / prognostic technology for aircraft generators. The design will be developed and a prototype system based on the design concept(s) will be fabricated. Through laboratory testing and characterization experiments, the viability of the system’s ability to diagnose failure modes and predict remaining life for an aircraft generator will be demonstrated. A detailed plan for software / hardware certification, validation, and method of implementation will be provided. Phase III will encompass complete packaging and integration of the prototype health monitoring system for use in a Navy aircraft platform, complete safety of flight certification, and perform a flight demonstration. It will also include final optimization of the diagnostic / prognostic system and its user interface.