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Winch Gearbox Prognostics & Health Management
Navy SBIR 2010.1 - Topic N101-024 NAVAIR - Mrs. Janet McGovern - [email protected] Opens: December 10, 2009 - Closes: January 13, 2010 N101-024 TITLE: Winch Gearbox Prognostics & Health Management TECHNOLOGY AREAS: Air Platform ACQUISITION PROGRAM: PMA-299, H-60 Helicopter Program; Sea Shield RESTRICTION ON PERFORMANCE BY FOREIGN CITIZENS (i.e., those holding non-U.S. Passports): This topic is "ITAR Restricted." The information and materials provided pursuant to or resulting from this topic are restricted under the International Traffic in Arms Regulations (ITAR), 22 CFR Parts 120 - 130, which control the export of defense-related material and services, including the export of sensitive technical data. Foreign Citizens may perform work under an award resulting from this topic only if they hold the "Permanent Resident Card", or are designated as "Protected Individuals" as defined by 8 U.S.C. 1324b(a)(3). If a proposal for this topic contains participation by a foreign citizen who is not in one of the above two categories, the proposal will be rejected. OBJECTIVE: Develop and demonstrate a Winch Gearbox Prognostics & Health Management System suitable for utility applications in a modern rotary wing aircraft. DESCRIPTION: Modern rotary wing aircraft have a number of utility winching/reeling systems for cargo, rescue, and sensor deployment applications. On the H-60, examples include the Airborne Mine Countermeasures � Carriage, Stream, Tow, and Recovery System (AMCM CSTRS) Winch System, rescue hoist, and the Airborne Low Frequency Sonar (ALFS). Unexpected degradation or failure of these systems can cause serious mission, reliability, maintenance, and logistical impact. A Winch Gearbox Prognostics & Health Management System could increase reliability and mission availability by accurately determining which parts are showing initial signs of failure, but remain usable to perform a mission with some degree of confidence for a predicted amount of time. This system should detect signs of degradation or failure precursors through advanced sensing techniques, integrated through software and predictive algorithms, and have available displays to both the user/winch operator and maintenance personnel. Displays or alerts identifying specific failure conditions and remaining life until maintenance is required, are desirable. The system needs to be lightweight, easily maintainable in and of itself, have a small footprint, and require minimal power interface with existing aircraft systems (a self-powered, wireless system of sensors would be preferable but is not mandatory). The system should be easily retrofitted to existing winch gearbox designs and existing H-60 Health & Usage Monitoring System (HUMS) Although there are some Rotary Wing Propulsion Gearbox systems that utilize HUMS technology very effectively, they do not cover the larger suite of potential degraders and Prognostics & Health Management goals intended to be accomplished here, especially on utility-type gearbox units. Potential areas for sensor development include but are not limited to: Lubricant quality/quantity detection, Signs of Gear mechanical component wear indication (wear particles in oil, etc.), Gearbox temperature and its rate of change, Gearbox vibration, Increase in Gear tooth backlash/chatter, Seal integrity and Detection of Lubricant leakage and/or rate of change of leakage. The challenge is to design and test a Winch Gearbox Prognostics & Health Management System that incorporates integral electronics capable of providing reliable operation in a difficult thermal, vibration and potentially corrosive maritime environment. As the goal is to develop a generally applicable Winch Gearbox Prognostics & Health Management System technique and system, no specific target Winch Gearbox is identified. PHASE I: Identify and develop a design for a Winch Gearbox Prognostics & Health Management System. Determine the feasibility of such a design by analyzing functionality and suitability for relevant aircraft applications. PHASE II: Develop, demonstrate and validate the Winch Gearbox Prognostics & Health Management System. Conduct performance and qualification-type tests with and without pre-planned failure modes to verify the system developed in Phase I accurately identifies failure causes/modes. Evaluate and modify the design to address any shortcomings found in testing. PHASE III: Transition the design to applicable platforms that can utilize a Winch Gearbox Prognostics & Health Management System. PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: The Winch Gearbox Prognostics & Health Management System would have direct application to Winching/Reeling systems on commercial aircraft such as Search & Rescue aircraft, Police/Security helicopters, Logging Operation Aircraft, and Off-Shore Oil Rig aircraft operation. Other potential applications include industrial control and heavy equipment used in construction and mining operations. Indirect application of the technology to other non-winch gearbox systems appears feasible, and could be even broader to perhaps encompass commercial aircraft utility systems of many types as well as Propulsion Gearbox Prognostics & Health Management with capabilities above those of current HUMS-type systems. REFERENCES: 2. Ousachi, Mark; Scott, Andrew; Yee, David; Hosmer, Thomas; Daniszewski, Dave; ASCTI, Troy, MI; "Embedded Diagnostics and Prognostics Wireless Sensing Platforms"; http://www.stormingmedia.us/86/8673/A867344.html 3. Raytheon Company, "AN/AQS-22 ALFS, Airborne Frequency Sonar"; http://www.raytheon.com/businesses/rids/products/rtnwcm/groups/public/documents/ content/rtn_bus_ids_prod_anaqs22_pdf.pdf KEYWORDS: Winch; Gearbox; Prognostics; Health Management; Failure Prediction; Gear Wear
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