PREDICTING THE HEALTH OF ROTOCRAFT DRIVETRAINS IN REAL-TIME

Sigpro's embedded systems designs for NASA have helped its Ames Research Center become an internationally recognized leader in on-line diagnostics of rotorcraft gearbox failures. Partnership with Sigpro over a seven-year span led to development of a full lab and flight facility, producing data and analyses that help predict rotorcraft system component health in real-time.

Customer Requirement

• As a first step to validating untested algorithms in flight situations, researchers at the Computational Sciences Division of NASA Ames required the design and implementation of a computer system to collect in-flight vibration data and related sensors from rotorcraft drivetrains for analysis and post-processing.
  
  
• Systems and development efforts expanded to include the ultimate program goal of predicting drivetrain component health in real-time.
  
  
• System requirements included the following:
  • Sensor selection and placement.
  • Embedded data acquisition and signal processing architecture.
  • Flight planning (pilot directives) and database archiving.
  • Advanced signal analysis.

Sigpro Approach

• Develop a ruggedized computer to perform sensor data acquisition and monitor aircraft instrumentation.
  • Flexible: hardware operational on multiple aircraft; software architecture allows reuse of all key components.
  • Expandable: features include real-time recognition and prediction capabilities.
    
    
• Define a unified approach to flight plans, database archive and access.
  • Compatible with existing and emerging ground-based "ironbird" experiments and analysis.
    
    
• Develop advanced computational methods to identify anomalies in helicopter transmission.

Key Results:

• The Sigpro solution, called HealthWatch, collected and
  analyzed:
  • Over 100 GB of data;
  • During 40 hours of flight time;
  • Across three helicopters and two ironbird test stands.
    
    
• Identification methods were developed which will be used to improve rotorcraft operational safety and lower field maintenance costs.
  • This innovative work has led to industry publications and patent filings.
    
    
• R&D Program continues, now with:
  • Significant lab tools and expertise
  • HealthWatch II system
  • Application to fixed-wing aircrafts

Customer Satisfaction:
The NASA team has come to rely on Sigpro as an integral part of their "Healthwatch" project team. Sigpro's contribution to the success of "Healthwatch" has earned us an ongoing relationship for the development and delivery of Healthwatch II, the second generation rotorcraft vibration monitoring system.

For more information on this project, please go to
http://ic-www.arc.nasa.gov/projects/siglab/