Colonel Paul Croisetiere Program Manager, H-53 Heavy Lift Helicopters U.S. Naval Air Systems Command AHS International Helicopter Safety Symposium Montreal, Quebec 28 September 2005 Integrated Mechanical Diagnostic System (IMDS) Contribution to Helicopter Safety Improvement

P Drive /Program Management/Briefs/Future/ IHSS Symposium2 Outline Navy/USMC Legacy Helicopter Fleet IMDS Description –Functional Capabilities –Safety-Enhancing Capabilities IMDS Growth and Future Applications

P Drive /Program Management/Briefs/Future/ IHSS Symposium3 Navy/Marine Corps Legacy Helicopters

P Drive /Program Management/Briefs/Future/ IHSS Symposium4 Navy HUMS Program Mandate Result of a 1993 VH-60N mishap during a maintenance flight –H-53 designated lead-the-fleet platform for common helicopter IMDS CNO mandate to incorporate avionics safety systems –Ground Proximity Warning System (GPWS) –Global Positioning System (GPS) navigation –Crash-Survivable Flight Incident Recorders (CSFIR) –Integrated Mechanical Diagnostic Systems (IMDS) Production program for H-53 and SH-60 began in 1997, with H-1 added in –Built by Goodrich Corporation, Fuel & Utility Systems Div.

P Drive /Program Management/Briefs/Future/ IHSS Symposium5 IMDS Description Full-time onboard usage and diagnostic monitoring –Engines –Drive train –Rotor system Also tracks: –Operational limit exceedances –Operational and structural usage parameters Flight data is downloaded post-flight for further diagnosis and reporting to NALCOMIS System also on UH-1Y, AH-1Z, MH-60R/S, Army UH-60L/M and Sikorsky S-92

P Drive /Program Management/Briefs/Future/ IHSS Symposium6 IMDS Enhances Flight Safety IMDS provides valuable safety enhancement –Diagnostic drive train monitoring –In-flight alerting –Flight data recorder options –Supports systemic improvements, such as Military Flight Operations Quality Assurance (MFOQA) –IMDS reduces maintenance

P Drive /Program Management/Briefs/Future/ IHSS Symposium7 Diagnostic Monitoring IMDS monitors the complete mechanical drive train –27 gears –28 shafts –71 bearings Automatic health calls are currently not fully enabled –Requires adequate experience sample to set appropriate triggers –Health calls being made by engineering, pending more data CH-53E example

8 Diagnostic Monitoring #1 HSS Inspected and re-balanced. No visible defect found Replaced coupling at request of the IMDS team Normal flight data after maintenance Example: SH-60B #1 High-Speed Shaft Coupling, BuNo

9 Diagnostic Monitoring Example: CH-53E #1 Nose Gearbox, BuNo Gear tooth fragment found by chip detector Gearbox removed First chip detector fuzz burn-off noted

P Drive /Program Management/Briefs/Future/ IHSS Symposium10 IMDS Success Stories GeneralSpecifics Finds aircraft problems that may go undetected HSL-41 noted high IMD vibe signature from #3 hangar bearing; subsequent ATABS data collection showed vibes within limits. Removal and inspection of bearing and shaft showed both worn beyond limits. HSL-41 noted multiple engine chip lights recorded by IMDS but cockpit chip caution light did not illuminate. Inspection revealed faulty chip detector filled with chips. Finds aircraft problems before scheduled maintenance HMT-302 automatically acquired ROTABS data showed vibration out of limits. Inspection revealed three of seven PCR bearings worn beyond limits. HMT-302 identified impending failure of #3 engine by strip chart. Engine was approaching high time. Subsequent inspection indicated excessive wear to power turbine rotor section. Significantly reduces troubleshooting time HSL-41 during initial FCF ground turn, IMDS indicated high vibration from drive shaft bearing. Inspection revealed bearing had disintegrated. ATABS would not have pinpointed problem for at least three more ground turns. HMT-302 utilized strip chart function to correct engine sympathetic start problems. Able to correctly identify which hydraulic start valve caused “bleed over”. Enables squadron to do required jobs faster HMT-302 and HSL-41 have noted that main RTB FCFs can be done within one flight. HMT-302 has noted reduction in number of required engine performance tests. Able to identify when an invalid check was performed (i.e., T5 not allowed to stabilize, incorrect OAT readings, etc.).

P Drive /Program Management/Briefs/Future/ IHSS Symposium11 In-flight Alerting All IMDS data is available to the crew Not every IMDS find is brought to the crew’s attention in flight –System currently annunciates NATOPS exceedances –Alerting for imminent failures requires: Larger statistical sample of data Rigorous safety hazard analysis Expectation is that continuous, long-term trending will reveal failures early

P Drive /Program Management/Briefs/Future/ IHSS Symposium12 Flight Data Recorder Interface IMDS enables options for Cockpit Voice/Flight Data Recorder (CVFDR) –Current IMDS provides CVFDR interfaces –P 3 I version will combine the Main Processor Unit (MPU) with a crash- protected CVFDR IMDS can provide any parameter it captures to a CVFDR –Limited only by available memory IMDS data already provides: –Complete data for every flight –Flight-to-flight trending –A powerful tool for mishap investigation

P Drive /Program Management/Briefs/Future/ IHSS Symposium13 Military Flight Operations Quality Assurance (MFOQA) A knowledge management process –using flight data downloaded after every flight –to provide quantitative performance information regarding aircrew and aircraft performance –to improve training, operational readiness and safety. IMDS data files support MFOQA applications –Sufficient parameters and data rates to be useable –No redundant data collection system required

P Drive /Program Management/Briefs/Future/ IHSS Symposium14 IMDS Road Ahead Vision for system maturation –Requires data from more installed systems Target areas for improving the system –Reliable health calls throughout the mechanical drive train –Begin the move to condition based maintenance –Changes to maintenance concepts –More information in the hands of users Application of HUMS as a mature tool in the next generation of rotorcraft

P Drive /Program Management/Briefs/Future/ IHSS Symposium15 Cost Savings Through Diagnostics Fault-based maintenance is an expensive practice –Reduces availability –Drives unscheduled maintenance –May involve collateral damage or flight mishap Condition-based maintenance (CBM) is possible – IF you can first assess “condition” –Reduced O&S costs –Increased safety –Increased reliability and availability –More efficient use of personnel through application of technology Diagnostic systems, such as IMDS, are key enablers of CBM

P Drive /Program Management/Briefs/Future/ IHSS Symposium16 Diagnostic Systems for the Future Helicopter Fleet NAVAIR is firmly committed to HUMS Enhances current/future readiness Enhances current/future readiness Reduces cost of doing our business Reduces cost of doing our business Improves agility of our forces Improves agility of our forces NAVAIR is firmly committed to HUMS Enhances current/future readiness Enhances current/future readiness Reduces cost of doing our business Reduces cost of doing our business Improves agility of our forces Improves agility of our forces

17 Questions