Sustainment_Strategic_Plan_-_for_FERST.pdf

Sustainment S&T Strategic Plan

DISTRIBUTION STATEMENT A: Approved for Public Release, pr 3483

Aviation Development Directorate – Aviation Applied Technology Directorate

U.S. Army Aviation and Missile Research, Development, and Engineering Center

8 December 2017

Sustainment Strategic Plan:

Details

• Scope

• Baseline

• Technology Effort Objectives (TEO) Aircraft Reliability TEO State Awareness TEO Operational Availability (Ao) TEO Maintenance Free Operational Period (MFOP) TEO

• Acronyms

Presenter Presentation Notes Currently we are focusing on integrating system diagnostic and prognostic assessments into an overall aircraft state awareness that can be used drive mission and maintenance planning, as well as enable aircraft adaption to continue to safely operate unsustained.

Automated approaches are being pursued to reduce the current maintenance burden while providing detailed records for improved maintenance strategies and component designs.

Intentional design choices that resist operational and environmental damage (e.g. fatigue & corrosion) as well as can reduce the vulnerability to (or tolerate) hostile threats are being matured and demonstrated. Aircraft-level trades are being made to identify and eliminate maintenance drivers. The goal is to drive up overall aircraft level reliability, ultimately improving Ao rates and MFOP duration while maintaining aircraft performance.

• Maintenance Strategy o Aircraft Design o State Awareness o Data Analytics o Prognostics o Adaptation o Fleet Life Management

• Aircraft Design Decisions o Materials o Design Features (redundancy) o Usage o Operational Environment

• Doctrine o Policy

• Standards

Sustainment Strategic Plan:

Scope

• Logistics o Aviation Records o Enterprise System o AGSE (general aviation) o PGSE (platform specific) o Other Support Equipment o Spare Parts o Consumables (e.g. fuel) o Personnel

• Practices o Train o Inspect o Diagnose o Clean o Repair o Replace

Fielded Systems

• AH-64E

• UH-60M

• CH-47F

• CH-53K

• V-22

• Gray Eagle

• Hunter

Sustainment Strategic Plan:

Baseline

• 3 (actual) / 2 (doctrinal) level maintenance

• Manual inspections

• Calendar / Flt time based maintenance intervals

• Fleet health state management

• TBOs / Retirement intervals

• Segregated, platform specific sustainment systems (on & off-board)

• Rigid logistics footprint

• Safe-life qualification

• Manual record keeping

• Specialized MOS training

• Interactive Electronic Tech Manual

• Sustainment treated as cost (not an attribute)

• Failure based criteria (not health based)

• Op tempo limited by maintenance

• Ground based diagnostics / NDI

Physical (2015):

Processes & Procedures (2015):

• Regime Recognition

• Dynamic component CI’s & HI’s

• CBM+

• Dedicated physical load & damage sensors

• HUMS limited to vibration & parametric data

• Component-level diagnostics

• “Big Data” collection

• Flight data recorders

• Engine FADEC

• Automated power assurance

• Composite repair

• BIT

Technology (TRL6+)

Aircraft Reliability TEO Durability and inherent reliability of the platform and its mission systems to include the state awareness subsystem. Contributions achieved through intelligent integrated and optimized design; durable materials; redundancy and damage tolerance; distributed and multifunctional sensing and processing…

State Awareness TEO Comprehensive understanding of installed configuration, health of the aircraft, and state of the fleet. Contributions achieved through accurate sensing capability (POD and confidence); robust data analytics; and integrated global monitoring with aircraft-level reasoning... Solutions must be affordable in terms of cost, space, weight, and power.

Operational Availability TEO Percentage of time that a system is operationally capable of performing an assigned mission (uptime / total time). Contributions achieved through operationally durable platforms, highly reliable and adaptable systems, inspectable and repairable designs, real-time diagnostics, accurate remaining service life prognostics, and agile logistics systems...

Maintenance Free Operational Period TEO Period during which the aircraft operates without the need for any sustainment actions.

Contributions achieved through high inherent platform reliability, redundant and reconfigurable systems, real-time health state awareness, probabilistic risk assessment… Both MFOP duration and any restoration level of effort in a high operational tempo are considered.

Technology Effort Objectives

Aircraft Reliability TEO

Availability, Affordability, Deployability, Footprint

Concepts Focus Area Mission Systems Focus Area

OS&S Focus Area Platform Power Focus Area

TEOs

Operational Availability Maintenance Free Operational Period

Sustainment Concepts, Design & AnalysisStructures

Focus Areas

Year Goal

(Baseline) Varies

2020 0.75

2025 1.0

2030 1.25

2040 --

Technical Challenges / Technology Gaps

• Designing for operational durability and ultra-reliability adds weight

• Operation in extreme environments, damaging conditions, & high op-tempo

• Requiring / specifying sustainable platforms

• Predicting life cycle costs

Approaches / Programs

• Future Embedded Rotorcraft Sustainment

Technologies

• Ultra-Reliable Design

• Component Prognostics for Aviation Systems

• Combat Tempered Platform

• Aircraft & Aircrew Protection

• Future Advanced Rotorcraft Drive System

• Rotor Durability

Description: Durability and inherent reliability of the platform and its mission systems Parameter: Design Service Life / Obsolescence Life Definitions: Design Service Life - Number of years (flight hours, flight cycles, or landings) established at design, during which the rotorcraft is expected to maintain its integrity when flown to the design usage and maintained as required.

Obsolescence Life - Number of years a rotorcraft component is in service before it is replaced for obsolescence, including factors such as growth and redesign (e.g. airframe is the life of the aircraft, but avionics is five years).

Aircraft Reliability State Awareness

State Awareness TEO

Availability, Affordability, Deployability, Footprint

Concepts Focus Area Mission Systems Focus Area

OS&S Focus Area Platform Power Focus Area

TEOs

Operational Availability Maintenance Free Operational Period

Sustainment Concepts, Design & AnalysisStructures

Focus Areas

Year Goal

(Baseline) <10

2020 50 SC

2025 90 SC

2030 75 MC

2040 90 MC

99.9

Technical Challenges / Technology Gaps

• Affordable in terms of space, weight, and power

• Sensor system reliability & durability

• High-confidence data analytics

Approaches / Programs

• Future Embedded Rotorcraft Sustainment

Technologies

• Component Prognostics for Aviation Systems

• Autonomous Sustainment Technologies for

Rotorcraft Operations

• Capability-Based Operations & Sustainment

Technologies

• Integrated Hybrid Structural Management

System

• Material State Awareness

Description: Comprehensive understanding of installed configuration, health of the aircraft, and state of the fleet

Parameters: (1) Percent coverage of Safety Critical (SC) and Mission Critical (MC) items

(2) Accuracy of determination (including sensor data and data analytics methods) compared to ground truth

Definitions: None

Aircraft Reliability State Awareness

Operational Availability TEO

Availability, Affordability, Deployability, Footprint

Concepts Focus Area Mission Systems Focus Area

OS&S Focus Area Platform Power Focus Area

TEOs

Operational Availability

Maintenance Free Operational Period

Sustainment Concepts, Design & AnalysisStructures

Focus Areas

Year Goal

(Baseline) 62 – 82

2020 83

2025 85

2030 90

2040 93

Technical Challenges / Technology Gaps

• Effectively sustaining two generations of fleet concurrently

• Rapid deployment / logistics agility

• Seamless integration into joint sustainment enterprise

• Network, communication denied operational environments

• Managing life cycle costs

Approaches / Programs

• Future Holistic Aviation Sustainment

Technologies

• Component Prognostics for Aviation Systems

• Autonomous & Robotic Remote Refueling

Point

• Future Sustainment Concept Study

• Joint Multi-Role Tech Demo

• Digital Twin

• Autonomic Logistics Information System

• Integrated Sustainment SIL

Description: Percentage of time that a system is operationally capable of performing an assigned mission

Parameter: Ao = MTBM / (MTBM + MMT + MLDT) Definitions: MTBM includes Unscheduled MMH / Flt Hr & Scheduled MMH / Flt Hr

MMT includes prognostics capability & versatile people or tools MLDT includes lead time and logistics agility

Aircraft Reliability State Awareness

MFOP TEO

Availability, Affordability, Deployability, Footprint

Concepts Focus Area Mission Systems Focus Area

OS&S Focus Area Platform Power Focus Area

TEOs

Operational Availability MFOP

Sustainment Concepts, Design & AnalysisStructures

Focus Areas

Year Goal (hrs)

(Baseline) < 5

2020 25

2025 100

2030 240

2040 480

Technical Challenges / Technology Gaps

• Balancing MFOP duration with restoration effort

• Balancing durability with performance

• Changing design, qualification, and life management approach

• Intelligent & adaptable aircraft

• Varying op-tempo

Approaches / Programs

• Future Embedded Rotorcraft Sustainment

Technologies

• Autonomous Sustainment Technologies for

Rotorcraft Operations

• Combat Tempered Platform

• Aircraft & Aircrew Protection

• Adaptive Vehicle Management System

• Future Affordable Turbine Engine

Description: Period during which the aircraft operates without the need for any sustainment actions

Parameter: Maintenance Free Operational Period Duration (hrs) Definitions: None

Aircraft Reliability State Awareness

Acronyms

Aviation Ground Support Equipment (AGSE) Platform Ground Support Equipment (PGSE) Condition Indicator (CI) Health Indicator (HI) Condition Based Maintenance Plus (CBM+) Health and Usage Monitoring Systems (HUMS) Full Authority Digital Engine Control (FADEC) Built in Test (BIT) Flight (Flt) Time Before Overhaul (TBO) Non-Destructive Inspection (NDI) Probability of Detection (POD) Military Occupational Specialty (MOS) Mean Time Between Maintenance (MTBM) Mean Maintenance Time (MMT) Mean Logistics Down Time (MLDT) Maintenance Man Hours (MMH)

AMRDEC Web Site www.amrdec.army.mil

Facebook www.facebook.com/rdecom.amrdec

YouTube www.youtube.com/user/AMRDEC

Public Affairs AMRDEC-PAO@amrdec.army.mil