Jason Holloway Aswin Sankaranarayanan Ashok Veeraraghavan Salil Tambe April 28, 2012.
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Transcript of © 2015 Real-Time Innovations, Inc. The Communications Platform for the Industrial Internet of...
![Page 1: © 2015 Real-Time Innovations, Inc. The Communications Platform for the Industrial Internet of Things™ Sumant Tambe Real-Time Innovations, Inc. May, 2015.](https://reader030.fdocuments.us/reader030/viewer/2022032705/56649dc85503460f94abdae1/html5/thumbnails/1.jpg)
© 2015 Real-Time Innovations, Inc.
An Extensible CBM Architecture for Naval Fleet Maintenance Using Open Standards
The Communications Platform for the Industrial Internet of Things™
Sumant TambeReal-Time Innovations, Inc.
May, 2015
Abdel-Moez E. Bayoumi, Alex Cao, Rhea McCaslin, Travis EdwardsCondition-Based Maintenance Center
University of South Carolina, Columbia, SC
Condition-Based Maintenance Center
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© 2015 Real-Time Innovations, Inc.2
Outline• Overview
– Condition-Based Maintenance (CBM)– South Carolina CBM Center– Real-Time Innovations (RTI)– Data Distribution Service (DDS)– Open System Architecture for CBM (OSA-CBM)
• Open Architecture using DDS and OSA-CBM Standards
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Consider the US industry is spending $260 billion each year on maintenance, of that $85 billion is lost on unneeded maintenance
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Improper Maintenance Costs
33% is wasted on unnecessary maintenance
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Maintenance Management Methods
Fix it when it fails
Continuous monitoring of actual conditions
Fixed time, calendar or operating hours
Time-BasedPreventive
Failure-BasedCorrective
Condition-Based· Connect· Analyze· Action
Predictive
Maintenance Practice
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South Carolina CBM Activities and Objectives
2006
2004
1999
1998
1996
2007
2009
2015
2010
2013
Predictive Maintenance & Health Score
Vibration Control Initiative
Structural/Regime Recognition and Damage Fraction Calculations
University of South Carolina (USC) Helicopter Test Stand
Blade wedges improves accuracy in track adjustments/saves blades
AWR allows track and balance adjustments without test flight
USC Cost Benefit Analysis (Reduced O&S cost, MTF reduction)
Last change to DA PAM 738-751
VMEP development begins on AH-64 A
Tail and Main Rotor Drivetrain Testing
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Partnerships and Collaborations
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CBM Areas of Research
DoD Funding 2008$15M & 5 years
DoD Funding2013$15M & 5 years
IM_13_ 7148_finalResearch
Focus
Cost Benefit Analysis
(ROI)Component
Testing
Tribology (Friction,
Lubricants, Wear)
Advanced Signal
Processing
Natural Language
Processing
Predictive Analytics
Diagnosis, Prognosis, &
Life Prediction
USC Research Infrastructure ~ $8M
Interdisciplinary• Medical• Business• Engineering• Computer Science
6 Faculty Members5 Military Personnel2 Post Docs6 PhD Students6 MS Students8 Undergraduates1-2 HS Students
Data Collection
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Benefits of CBM
Maintenance man hoursDays in maintenanceTime between overhaulDays pending repair
Total parts costPremature part failureMaterial cost avoidanceOperational cost avoidance
PerformanceMoraleSense of safetySense of time savingsConfidence
Direct cost benefits
Intangible benefits
Time savings
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• ROI: Largest ROI of any Army funded project at 20.2:1
• Economic Impact: Overall Economic Impact exceeds $250M over the past 10 years
• Cost Avoidance: Overall Cost Avoidance for the US Army exceeds $125M over the past 10 years
• Testing Hours: Over 9000 testing hours completed on the USC Test Stands examining multiple faults
• TBO: Time Between Overhauls increased on multiple components by up to 500 hours
15-Year History of CBM at USC
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Testing Capabilities at USC
Tail Rotor Drive Train (TRDT)/Main Rotor Swashplate (MRSP) on actual
AH-64D
TRDT/MRSPtest stands
at USC
FHB
#4#5
#6
TGB
AHBIGB
#3
Sensing• Vibration• Temperature• Speed• Torque• Metals in oil• Acoustic• Doppler Radar• Strain gauges
TRSP
MRSP
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Objective:Demonstrate whether the aircraft could continue to operate with a leaking output seal until the aircraft reached a major maintenance event
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Tail Rotor Gearbox Output Seal Study
Approach:Discovered that grease was moving freely between the main gear compartment into the static mast
Outcome:‒ Maintenance practice changed from replacing entire TGB
assembly to either replacing the output seal or continue adding grease
‒ Led to reduction in part costs, necessary downtime, and labor requirements
‒ New output seal removal tool was designed and is currently used in the field
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U.S. Army Aviation and Missile Command | AMCOM Logistics CenterUNCLASSIFIED / FOUO
Cost-Wise Readiness (CWR) Solution through USC CBM Center Innovation & Maintenance Improvement
Return on Investment (ROI)
Technical Bulletin ReleasedOct 2009
Present Cost Avoided
10/09-12/13$12.68M
Project Cost $627K
ROI 20.22 : 1
Issue: Tail Rotor Gear BoxRemovals Due to Leaking
Required Depot Level Repair
Solution: Repair Developed by University of S. Carolina (USC) CBM
Center & Team Redstone
Followed by IETM Update
Yields within 51 Months Since Implementation:
AH-64 TRGB Output Seal Field RepairIncreasing Readiness & Reducing Need for Spares
Greatest ROI to Date
Avg. Cost Avoided: $2.98M/Year
Metrics Before After
Demands/ 10K FH 10.58 6.71
36.5
5%
324 Fewer TRGBs Demands in 51 Months
Benefits Up 8.84% from Prior Quarter; Significant Contributor to $53.25M Sum Costs Avoided
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Objective:Produce a set of tools to be used as an indicator on the success of a system maintained by CBM
Approach:– Accurately simulate a full drivetrain– Use predictive analytics to determine component life and condition– Automate maintenance action reports article replacement– Correlate how maintenance affects supply chain
Outcome:– Longer time on-wing for PPMS monitored components– Extended TBO on articles– Higher morale for the soldiers– Increased sense of safety for entire crew
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Sustainment Project
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Preventive Predictive Maintenance (PPM)
Predictive Tools
Useful Life
Health Condition ...Design
Phase II – PPM: PHYSICS MODELING Phase III – PPM:
INTEGRATION & VALIDATION
Phase I – PPM: MEASUREMENT
CORRELATIONS & IMPLEMENTATION
© 2014 QMT, LLC. All Rights Reserved © 2014 QMT, LLC. All Rights Reserved
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QMT & CBM@USC Confidential 15
Connecting Components with DDS
DATA BUS
Publisher Publisher
Subscriber
Publisher
Subscriber
Publisher
Subscriber
NI LabVIEW Modeling End User 1 End User 2
Sensor Data
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• OSA-CBM specifies a standard architecture and framework for implementing CBM
• There are 4 primary OSA-CBM data classes: DataEvent, Configuration, Explanation and Extensible– DataEvent is the dynamic data
generated by an OSA-CBM module such as measurements
– Our prototype implementation of OSA-CBM uses DataEvent and related classes 16
OSA-CBM
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© 2015 Real-Time Innovations, Inc.
Real-Time InnovationsStandards-based Open Architecture forCondition-Based Maintenance
17
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© 2015 Real-Time Innovations, Inc.18
Industrial Internet of Things (IIoT)
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RTI Provides Connectivity Platform for Industrial IoT Systems• Industrial IoT Systems Interact with the Real World• Must adapt to changing environment• Cannot stop processing the information• Must react at the speed imposed by the environment
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© 2015 Real-Time Innovations, Inc.20
DDS: Data Connectivity Standard for the Industrial IoT
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RPC over DDS
2014
DDS Security
2012
Family of Specifications
DDSImplementation
Network / TCP / UDP / IP
App
DDSImplementation
App
DDSImplementation
DDS Spec
2004
DDSInteroperablity
2006
UML Profilefor DDS
2008
DDS forLw CCM
2009
DDS X-Types
2010 2010
DDS-STD-C++DDS-JAVA5
App
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© 2015 Real-Time Innovations, Inc.22
“Global Data Space” generalizes Subject-Based Addressing• Data objects addressed by Domain ID, Topic and Key• Domains provide a level of isolation • Topic groups homogeneous subjects (same data-type & meaning) • Key is a generalization of subject
Data Writer
Data Writer
Data Writer
Data Reader
Data Reader
Data Reader
Data Writer
Domain
Topic
Instance
Key (subject)
Data-Centric Model
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© 2015 Real-Time Innovations, Inc.23
Open System Architecture for Condition-Based Maintenance (OSA-CBM) Standard
OSA-CBM Functional Architecture
• OSA-CBM specifies a standard architecture and framework for implementing CBM
• The functional blocks are often provided by different vendors/teams due to vastly different skillset required to implement each
• An end-to-end CBM system must integrate them together somehow…
– Point-2-point– Bus Architecture
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Advisory Generation (AG)
Prognosis Assessment (PA)
Health Assessment (HA)
State Detection (SD)
Data Manipulation (DM)
Data Acquisition (DA)
Inflexible N2 Point-to-Point Communication
• Complex• Inflexible• Tightly-coupled• O(N2) connections• Not scalable• Encourages
custom protocols• Potential vendor
lock-in
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© 2015 Real-Time Innovations, Inc.25
Advisory Generation (AG)
Prognosis Assessment (PA)
Health Assessment (HA)
State Detection (SD)
Data Manipulation (DM)
Data Acquisition (DA)
OSA-CBM Data Model in DDS X-Types
Flexible Open Extensible Data Bus Architecture
• Simpler• Flexible• Loose-coupled• O(N) connections• Scalable• No custom
protocols• No vendor lock-in
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Example:Types for Data Acquisition (UML)
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© 2015 Real-Time Innovations, Inc.27
OSA-CBM Compliant
Data Acquisition
XML Representation
X-Types Representation
DDS DataWriter
OSA-CBM Compliant
Health Assessment and
Prognostics
XML Representation
X-Types Representation
DDS DataReader
OSA-CBM Data Model in DDS X-Types
CBM Dataflow via DDS
Transformation
Write
Reverse Transformation
Publish Subscribe
Read
ProcessAcquire
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© 2015 Real-Time Innovations, Inc.28
Modeling Data Acquisition Types using RTI Connext DDS
Option 1 Option 2
1. Manually write IDL for OSA-CBM (lot of it)2. Use RTI code-generator3. Write glue code from source data model
to the IDL-defined data model (again, lot of it)
4. Done!5. Example: Cranfield University [1]
1. Generate code from the OSA-CBM XSD using a third party code generator
2. Describe application-level types in C++ using RTI RefleX [2]
3. Auto-generate glue code from C++ application data model
4. Done!5. Example: RTI Github OSA-CBM [3]
[1] Tarapong Sreenuch, Antonios Tsourdos, Ian Jennions, and Peter Silson, “Application of the Data Distribution Service for Implementing OSA-CBM Standard”, Infotech@Aerospace 2011.[2] http://rticommunity.github.io/rticonnextdds-reflex/ [3] https://github.com/rticommunity/rticonnextdds-reflex/tree/master/test/osacbm
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© 2015 Real-Time Innovations, Inc.
Thank You!