كريم عابدي Advanced Structural Systems (2) سیستم های ساختمانی پیشرفته ( 2)
Structural In-Service Monitoring of Advanced Combat ...
Transcript of Structural In-Service Monitoring of Advanced Combat ...
14年 5月 29日DGQT 95/
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Ce document est la propriété de Dassault Aviation, il ne peut être utilisé, reproduit ou communiqué sans son autorisation.
TITRE DE LA PRESENTATION
Advanced Combat Aircraft HUMS Division DÉFENSE 1
HUMS 2001
Structural In-Service Monitoringof Advanced Combat Aircraft:
Operational Benefits
X. Labourdette,Dassault Aviation,
Military Customer Support Division,78, quai Marcel Dassault,
Cedex 300, 92552 Saint-Cloud Cedex,France
Advanced Combat Aircraft HUMS Division DÉFENSE 2
HUMS 2001 CONTENTS
• Simple facts
• Structural Design Methodology
• The Rafale Health and Usage Monitoring System
• Operational Benefits
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TITRE DE LA PRESENTATION
Advanced Combat Aircraft HUMS Division DÉFENSE 3
HUMS 2001
• Simple facts
• Structural Design Methodology
• The Rafale Health and Usage Monitoring System
• Operational Benefits
Advanced Combat Aircraft HUMS Division DÉFENSE 4
HUMS 2001
Emergence of the need for more advanced systemsEmergence of the need for more advanced systems
SIMPLE FACTS
• Structural monitoring of previous generation aircraft
dedicated
computer
strain
gauges
mass, power, reliability penaltypoor ageing, drift, re-calibration
+
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TITRE DE LA PRESENTATION
Advanced Combat Aircraft HUMS Division DÉFENSE 5
HUMS 2001
• Simple facts
• Structural Design Methodology
• The Rafale Health and Usage Monitoring System
• Operational Benefits
Advanced Combat Aircraft HUMS Division DÉFENSE 6
HUMS 2001
Initial Conditions Aerodynamic LoadsFatigue Spectrum
Continuous Follow-up of all Dassault Aircraft Programs
Final DesignStructure Limit Loads
First Inspection & Maintenance Program
Initial Design LoadsDurability & Damage Tolerance
Development Components TestsAirframe Cell TestPrototype Flights
Inspection & MaintenanceProgram Updating
Fatigue Index Extension
Operational Flights Structure Limit Loads
Fatigue Test on Aged Aircraftfrom Fleet + Operational Loads
STRUCTURAL DESIGN METHODOLOGY
GENERAL
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TITRE DE LA PRESENTATION
Advanced Combat Aircraft HUMS Division DÉFENSE 7
HUMS 2001
Flight Tests on
Instrumented A/C
General
F.E.M.
LoadsCalibration
StructureLimitations
models calibration
and updating
BoundaryConditions / Loads
LoadsUpdating
Detailed
F.E.M.
AllowableCriteria
Validation
Documents
Aerodynamic
Base
Ground Tests
Partial & General
Flight ControlSystem
STRUCTURAL DESIGN METHODOLOGY
GENERAL VALIDATION PROCESS
Advanced Combat Aircraft HUMS Division DÉFENSE 8
HUMS 2001
Fzcanard
FzFrame 1
Fzmain gear
Fzarrester hookattachment
FFUS3
-400
-200
200
400
600
800
-400 -200 0 200 400 600 800
FU02FU01
prev
CA02
V006
FVLD3
-200
0
200
400
600
800
-200 0 200 400 600 800
VO11
VO12
VO09VO10
prev
Fuselage gauge Wing gauge
FE responses
CA01 :calibration
load
measures measures
FE responses
Measurement / Calculation Correlation: these ratio are injected in general FEM model
STRUCTURAL DESIGN METHODOLOGY
ON-GROUND CALIBRATION OF GAUGES
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TITRE DE LA PRESENTATION
Advanced Combat Aircraft HUMS Division DÉFENSE 9
HUMS 2001
Fuselage Stringer gauge( slope of My versus nz )
0
0.2
0.4
0.6
0.8
1
1.2
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8
Mach
+ 5 %
- 5 %
0
0.2
0.4
0.6
0.8
1
1.2
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8
Wing Root gauge( slope of Mx versus nz )
Mach
+ 5 %
- 5 %
Samples of Flight/Computation Comparisons
Winggauge
-1000
0
1000
2000
3000
4000
5000
1 s
t
Roll manoeuvre : strain response in time
STRUCTURAL DESIGN METHODOLOGY
FLIGHT TEST EXPLOITATION
++
If ratio “max measured/max. computed” is not # 1then aeroelasticity database is re-calibrated by
modifying aerodynamic database
Advanced Combat Aircraft HUMS Division DÉFENSE 10
HUMS 2001
• Lifting surfaces grids
• Boxes (fuselage andexternal stores)
General FE model withreference loads
Manoeuvreconditions
Aeroelasticcomputation
STRUCTURAL DESIGN METHODOLOGY
FLIGHT LOADS CONSTRUCTION
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TITRE DE LA PRESENTATION
Advanced Combat Aircraft HUMS Division DÉFENSE 11
HUMS 2001
Certification
Calibrated F.E. Model
with Reference Loads
Detail
Models
Specific
Analyses
Tests
Procedures
Criteria
Allowables
Direct Exploitation
Wing Box Attachment
STRUCTURAL DESIGN METHODOLOGY
STATIC AND FATIGUE VALIDATION PROCESS
Advanced Combat Aircraft HUMS Division DÉFENSE 12
HUMS 2001
Mass Distributions (structural & non structural)
Internal Monitoring Quantities
(strain gauges / structural resistance indicators)
Creation with CATIA (geometrical & material characteristics)
Clean A/C Configuration
STRUCTURAL DESIGN METHODOLOGY
GENERAL FINITE ELEMENT MODEL
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TITRE DE LA PRESENTATION
Advanced Combat Aircraft HUMS Division DÉFENSE 13
HUMS 2001
Arresting hook lug (3D)Elementary specimen (2.5D)
Fitting
Type of Models especially used for Fatigue Calculations
STRUCTURAL DESIGN METHODOLOGY
AIRFAME VALIDATION : DETAILED MODELS EXPLOITATION
Advanced Combat Aircraft HUMS Division DÉFENSE 14
HUMS 2001
Composite materials
Aluminium alloys
Titanium (SPF / SPF-DB)
Miscellaneous
STRUCTURAL DESIGN METHODOLOGY
RAFALE MATERIALS
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TITRE DE LA PRESENTATION
Advanced Combat Aircraft HUMS Division DÉFENSE 15
HUMS 2001
COMPONENTS & A/C
SUB-COMPONENTS
DETAILS
ELEMENTS
COUPONS
specificspecimens
genericspecimens
database
structurefeatures
STRUCTURAL DESIGN METHODOLOGY
TEST PYRAMID LOGIC (STATIC AND FATIGUE)
Advanced Combat Aircraft HUMS Division DÉFENSE 16
HUMS 2001
Fastenerhole area
Large cut-out
Impact Bolted joints
Examples of Composite Coupons
STRUCTURAL DESIGN METHODOLOGY
COUPON TESTS
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TITRE DE LA PRESENTATION
Advanced Combat Aircraft HUMS Division DÉFENSE 17
HUMS 2001
Used for Design Criteria & Allowable Construction
Bolted Joint Stiffeners(Composite)
STRUCTURAL DESIGN METHODOLOGY
GENERIC ELEMENTS TESTS
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TITRE DE LA PRESENTATION
Advanced Combat Aircraft HUMS Division DÉFENSE 19
HUMS 2001
Full Scale Test :
Fatigue (25 000 hours)
Static : Limit Load x 2
STRUCTURAL DESIGN METHODOLOGY
AIRCRAFT COMPONENT TESTING
Advanced Combat Aircraft HUMS Division DÉFENSE 20
HUMS 2001
• Airframe in development definition
• 110 load introductions
• 3 000 gages
• 50 displacement sensors
STRUCTURAL DESIGN METHODOLOGY
MECHANICAL TEST AIRFRAME
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TITRE DE LA PRESENTATION
Advanced Combat Aircraft HUMS Division DÉFENSE 21
HUMS 2001 STRUCTURAL DESIGN METHODOLOGY
EXTERNAL STORES VALIDATION
Advanced Combat Aircraft HUMS Division DÉFENSE 22
HUMS 2001
Air to Air
Air to Ground(Heavy)
P (°/s)
0 nz (g)
LOAD FACTOR
Roll rate
Design Envelope
STRUCTURAL DESIGN METHODOLOGY
EXTERNAL STORES VALIDATION
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TITRE DE LA PRESENTATION
Advanced Combat Aircraft HUMS Division DÉFENSE 23
HUMS 2001
Number of Exceedanceper 1 000 Flight Hours
Nz
(g) STATIC DESIGN
STATIC DESIGN
STRUCTURAL DESIGN METHODOLOGY
FATIGUE REFERENCE SPECTRUM
Advanced Combat Aircraft HUMS Division DÉFENSE 24
HUMS 2001
N criticalN current
ActualPropagation
Curve
Structure Fatigue Strength calculated with Reference Spectrum
Fatigue Validation Fatigue or Propagation Index > 100
Flight Number (N)
crack size Propagation CurveReference Spectrum
Reference Spectrum : XX Flight Hours equivalent to Indexes = 100
In-Service Spectrum : Computation of F.I. & P.I. Actual Consumption
STRUCTURAL DESIGN METHODOLOGY
FATIGUE & PROPAGATION INDEXES
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TITRE DE LA PRESENTATION
Advanced Combat Aircraft HUMS Division DÉFENSE 25
HUMS 2001
Local Stress Intensity FactorLocal Fatigue Parameters
Geometry ParametersComputation
Material Data Base
Safe Life
Crack Length
Flight
Number
2024 Wöhler Curve
0
50
100
150
200
250
300
350
400
1 e+3 1 e+4 1 e+5 1 e +6
Number of cycles N
sig
ma
(MP
a)
-2
-1
0
1
2
3
4
5
6
7
8
9
Nz
100
101
102
103
104
-
- 2
- 1
0
1
2
3
4
5
6
7
8
9
1 0
1 1
1 2
RAINFLOW
Fatigue Index Propagation IndexFatigue Validation Documents
STRUCTURAL DESIGN METHODOLOGY
FATIGUE VALIDATION : COMPUTATION PROCESS
Advanced Combat Aircraft HUMS Division DÉFENSE 26
HUMS 2001
• Simple facts
• Structural Design Methodology
• The Rafale Health and Usage Monitoring System
• Operational Benefits
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TITRE DE LA PRESENTATION
Advanced Combat Aircraft HUMS Division DÉFENSE 27
HUMS 2001 RAFALE HUMS
BASIC OPERATING PRINCIPLE
formattedcartridge
Pre-flightinspection
Shut down Post-flightinspection
Start up Flight
record initialization(tail number, date, time...)
maintenance datarecording
end ofrecording
A/C Mission Computer :
HUMSIn-flight
recorded data
Advanced Combat Aircraft HUMS Division DÉFENSE 28
HUMS 2001 RAFALE HUMS
CONCEPT - 1/3
Missioncomputer
• Local stress and fatigue depend on steering parameters
Monitors in real time peak-to-peak
values of steering parameters
Records steering parameters when
instantaneous peak-to-peak
exceeds pre-determined values
• All data are stored on a Mass Memory Cartridge
Detects and records static
exceedance on critical areas
(static operator database)
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TITRE DE LA PRESENTATION
Advanced Combat Aircraft HUMS Division DÉFENSE 29
HUMS 2001 RAFALE HUMS
CONCEPT - 2/3
GroundSupportStation
Reads and checks
data consistency
Computes local stress value on
each monitored area with tables
partial derivative tables
Determines peak-to-peak
value of local stress
Exploit static
exceedance on
critical areas
Performs Rainflow
counting
Sums up unitary index on
all peak-to-peak classes
(cumulative Miner law)
FI for last flight
Computes (PREFACE
model from ONERA)
threshold effect
PI for last flight
Advanced Combat Aircraft HUMS Division DÉFENSE 30
HUMS 2001
MassMemory
Cartridge
A/C Ageing metercomputation
Flight Fault Reportexploitation
MaintenanceManagement
System
Workprogram
Preventivemaintenance
operationCorrective
maintenanceoperation
Engine Ageing metercomputation
Structural fatiguecomputation
INU performancedisplay
Engine fileexploitation
Flight Fault Report:statistical analysis
Ground Support Station
RAFALE HUMS
CONCEPT - OTHER FUNCTIONS 3/3
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TITRE DE LA PRESENTATION
Advanced Combat Aircraft HUMS Division DÉFENSE 31
HUMS 2001 RAFALE HUMS
TYPICAL MAN-MACHINE INTERFACE
Advanced Combat Aircraft HUMS Division DÉFENSE 32
HUMS 2001
• Simple facts
• Structural Design Methodology
• The Rafale Health and Usage Monitoring System
• Operational Benefits
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TITRE DE LA PRESENTATION
Advanced Combat Aircraft HUMS Division DÉFENSE 33
HUMS 2001 RAFALE HUMS
OPERATIONAL BENEFITS - 1/3
• On-ground computation of indexes enable to:
re-compute at any time the structural health of any area,
in combination an accurate F.E. modelisation,
very easily support the software, since it is not flight-rated
save computing power on-board of the aircraft
monitor a high number of areas (# 30 on Rafale), thus
providing for an itemised following of structurally
significant elements
Advanced Combat Aircraft HUMS Division DÉFENSE 34
HUMS 2001 RAFALE HUMS
OPERATIONAL BENEFITS - 2/3
• On-board monitoring of a limited set of non-dedicated steering
parameters enable to:
save computing power on-board of the aircraft
devote this function to the mission computer only
save the mass, power, volume and reliability penalties
generated by a dedicated system
record a high number of flights in the memory cartridge (10)
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TITRE DE LA PRESENTATION
Advanced Combat Aircraft HUMS Division DÉFENSE 35
HUMS 2001 RAFALE HUMS
OPERATIONAL BENEFITS - 3/3
• Accurate modelisation enables to plan structural maintenance
out of the actual use of the aircraft
• Fully automatic processing and clear language reduces training
needs for structural life consumption assessment
• Simple inspection procedures associated with this index
concept enable to support structural inspection at Intermediate
Level throughout the aircraft life.