Les besoins en maintenance chez

EUROCOPTER : les principaux

axes damlioration de la
maintenance des hlicoptres

Helicopter Maintenance
Research in maintenance
Availability and cost modelling
Reliable Design
Maintenance credit
New Health monitoring solution
Innovative Diagnostic
RFID Logistic mean

Maintenance objectives
Cost

Decrease the maintenance costs

Make the maintenance work easier
Safety

Increase Safety with maintenance low cost actions

Availability

Increase the aircraft availability

Business

Improve the EC business in terms of Maintenance

& Service
Propose a meaningful service/product combination

helicopter maintenance specificities

Airplane
Wild body
Equipments all over the AC
Same product for each AC

Helicopter
vhicule compact
Centralized equipments
Personnalised and adaptable HC

helicopter maintenance specificities

Airplane

Helicopter

Long range

Take off and landing = stress

One mission type

A lot of different mission

High altitude

Less than 5000m

helicopter maintenance specificities

Airplane

Helicopter

Low vibration stress

Hight mechanical stress

Specific customer

Diversity of customer

Availability as priority

Failure localisation to
avoid no failure fond

The airplane and the helicopter are two vehicules using the same
maintenance mode but in different objectives and different stress.

The group
Helicopter Maintenance
Research in maintenance
Availability and cost modelling
Reliable Design
Maintenance credit
New Health monitoring solution
Innovative Diagnostic
RFID Logistic mean

Maintenance Research major axis

II - Reliable Design

I - Availability and cost modelling

III - Maintenance credit

IV - New Health monitoring solution

Equipments/
System

Sensors

Tools

Documentation

Diagnostic table
Evolution of diagnostic table,
Adaptability to helicopter's
options
Display of the results in order
to ease comprehension of
maintenance operations

Sensors
Intelligent sensors,
able to monitor and
send back their state

Sensor

Failures
localisation
Tools, on
ground

Computer

LRU
New developments
Integration of testability all
along design phases
Suppression of testability
demonstration

Trouble shooting
RTG
Troubleshooting

Trouble
shooting

Interface Failures

Test words emission

on interfaces
Old/new avionics
Interfaces
How to test COTS
and old avionics
interfaces

VI - RFID Logistic mean

V - Innovative Diagnostic

The group
Helicopter Maintenance
Research in maintenance
Availability and cost modelling
Reliable Design
Maintenance credit
New Health monitoring solution
Innovative Diagnostic
RFID Logistic mean

Scenario modeling
NTI 1

Inspection / Servicing

Base

Pilot
Flight engineer

(NTI 2)

A/C to Overhaul

Pilots

Failure

Flight
engineers

Flight Planning
Periodic inspection
Non scheduled maintenance
Trouble shooting

Certified
Station
NTI 1/2/3

Equipment to Overhaul
Engines
Manufacturer

Workshop
Planning

Availability modeling
7008 h=80%
Effective time of
availability

Flying time

500 h = 6%

6508 h = 94%

Servicing

Waiting time
Effective waiting time

473 h = 50%
1577 h = 18% /FH
Total time=
Time required=
8760 h

Effective time of
unavailability

946 h =
60%
Predictive
maintenance
period

Systematic maintenance period

473 h = 50%
Additional maintenance period

536 h = 85%
631 h = 40%
Unavailability time
for corrective
maintenance

180 h = 2%
Unavailability due to external
reason

Active time of
corrective
maintenance

Spares supplying
period
Failure research &
diagnosis period
Reparing period

95 h = 15%
Maintenance
implementation
period

Distribution of the life cycle costs

Performances
Ecodesign

Hardly
reducible

Reliability

Utilization
10%
i th
dr
Acquisition
aw
Ind
al
25%
Ma irect
inte
n
Internal ance
Mainten
ance
1500/h
Insurance
Direct
15%
Maintenance
Cost
35%

Maintainability

Production
costs

The group
Helicopter Maintenance
Research in maintenance
Availability and cost modelling
Reliable Design
Maintenance credit
New Health monitoring solution
Innovative Diagnostic
RFID Logistic mean

Reliability optimization

Product

Reliability
Process

Environment

The approach
Control of the avionic environment

Prediction of the future H/C

DMC

Constraints to
reduce

Data base of
DMC adjusted

Prevision of the constraints

profitable to control
Design of the reducing
constraints systems
Technico-conomical
evaluation of the systems

Profitability of
the systems
Selection of the most
profitable systems

Quantified
Systems

Which constraints to control ?

Where controling them ?

DMC
observed

Location in
The H/C

acc
DMC
predicted predicted

Calculator AP

6$/h

Nose

1,5

Visual MFD

5$/h

Instrument panel

acc
optim

DMC
optim

Saved
DMC

4 ,5/h

3/h

1 ,5/h

3/h

1,5

4/h

1/h

Temperature Spectrum
in observed environment
Temperature spectrum
in predicted environment
Temperature Spectrum
in controled environment

Design to Reliability

Profit of
DMC
(1)

Profit of
DMC

Reliability
service

Reliability
service

Thermal
atmosphere
(2)

Thermal
atmosphere

Thermal
service

Thermal
service

Technical
performances
(3)
Specification

(6)

(5)

Technical
performances

Cooling systems
service
Selection of the
product in the
market

(4)
Definition

The group
Helicopter Maintenance
Research in maintenance
Availability and cost modelling
Reliable Design
Maintenance credit
New Health monitoring solution
Innovative Diagnostic
RFID Logistic mean

Health monitoring for Maintenance

Health

Usage
Moteurs
Utilitaires

Data acquisition
on board
Trains

Warning

Avionique

Ground level
maintenance

Structure

maintenance Architecture

Detection / Localisation
Diagnostic
Troobleshooting
Maintenance tasks

maintenance Oprateur

Maintenance credits

TBO

TTF

Increase the Time Between Overhaul

H

Anticipation de panne
Maintenance corrective

Maintenance credits
Decision
support

Corrective
maintenance

Interface

Indicators

Health & Usage Monitoring System (HUMS)

Interpretation

Vibration
analysis

Acquisition

USAGE

HEALTH

Flight
data

HOMP

Maintenance credits
Health-based
maintenance planning

Decision
support

Maintenance credits
Interface

Vehicle Monitoring for Maintenance & Health

Management System
First failure
symptoms

Interpretation

Vibration
analysis

Acquisition

HEALTH

Oil
Analysis
ADHER

Before
failure

CORRELATION

Stress-Strain
Analysis

SHM

CESAR

USAGE

Flight
data

HOMP

The group
Helicopter Maintenance
Research in maintenance
Availability and cost modelling
Reliable Design
Maintenance credit
New Health monitoring solution
Innovative Diagnostic
RFID Logistic mean

New health monitoring solution for

Pronostic

For avionics

For Structural parts

Pronostic for avionic

Contraintes environnementales:
- Cycles thermiques
- Sollicitation vibratoires
- Corrosion chimique
- Hygromtrie

Dgradation lmentaire
induite

Micro-HUMS

integrated sentinel
Continuous monitoring
Evaluation of external
solicitations

SRU Pronostic
Implementation Prototype

environment
Identification
Calculation of
degradation
Sum of the elementary
damages
n
Micro-HUMS
Damage
= i
i CTFi

weak or
defective
population

BIHM DEGRADATION CALCULATION ALGORITHMS

Eurocopter Structural Monitoring

Propose a new concept for the maintenance and the

operational use of the airframe part of the helicopter
Integration of Structure Health Monitoring for :
Flight tests
Major incident
Repairing follow-up for difficult access points
To develop a specific tool to exploit diagnosis structure results
Maintenance tools for composite, metalic failure
diagnostic

Structural Health Monitoring - Ultrasonic

Sensors.
Materials of the Tail
Unit Demonstrator

A-Scan of the upper Skin

- Glass cloth / epoxy : 0.05 mm

- Bronze grid 50g/m
- 1 ply of carbon /epoxy fibre bi directional : 0.22
mm
- 3 plies of Carbon /epoxy fibre uni directional :
3 x 0.17 mm
- 1 ply of carbon /epoxy fibre bi directional : 0.22
mm
- Film of glue epoxy
- Sandwich of Nomex honeycomb: 15 mm
- 2 plies of hybrid carbon /glass fibre resin
epoxy: 0.25 mm
- Film TEDLAR

Ultrasonic imaging of the upper skin

Ultrasonic imaging of skin and core
Visualisation of Lamb wave fields

The group
Helicopter Maintenance
Research in maintenance
Availability and cost modelling
Reliable Design
Maintenance credit
New Health monitoring solution
Innovative Diagnostic
RFID Logistic mean

On board failure management

Problematic links to the aircraft diagnostic
False Failures: False warnings
Failure Localisation Ambiguity (intrinsic)
Failure Propagation

All these problematic lead to :

false removal (between 30 and 40% of maintenance
operations)
Longer maintenance time
Lost of confidence in the diagnostic tool
Customer is not satisfied

Diagnostic innovation
Sensor data
correlation
algorithm

Telemaintenance

AMC

SENSOR 1
SENSOR 2
SENSOR n

FDS
AFCS

Ethernet

Genera
te a
failure
algorit
hm
robust
to
option
al and
export
able to
other
helicop
ters

Correlation with
complementary
data
GSC

VMS
DISPLAY

Logical and Temporal

Correlation of failure
messages

Inte
grat
es
expe
rien
maintenance computer
ce
feed
back

The group
Helicopter Maintenance
Research in maintenance
Availability and cost modelling
Reliable Design
Maintenance credit
New Health monitoring solution
Innovative Diagnostic
Logistic mean

RFiD for logistic means

LOGISTIC ENVIRONMENT

Flotte hlicoptres

GROUND ENVIRONMENT

AERONEF ENVIRONMENT

Filiales rseau
mondial

FLEET MANAGEMENT
CONFIGURATION /
HEALTH ,
USAGE DATA /
WARNING
MESSAGES

DOCUMENTATION

(PN / SN )

Base
de
donnes
globale

F DA

TA

Analyse
usage / sant

Maintenance
data transfert

CON

Gestion de
configuration
Planning rvision

LINK WITH

Customer

stock

INDUSTRIE

Repair center

DATA CONCENTRATOR

BSITAG

RFiD for health monitoring

Concept :
Assume the part following with RFId integrated snesors
Wireless
On ground and in flight

Objective : Usage monitoring

HUMS
HUMS

HUMS

HUMS

In storage : monitoring of hter storage condition associated to the mechanical

containers
In usage : Monitor the real usage condition in the HC impact on flight
planning

Monitoring in
storage

Monitoring in flight

Thank you for

your attention