5 Steps to Heaven – A Rolls-Royce Perspective
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5 Steps to Heaven – A Rolls-Royce Perspective. Dr Ian K Jennions EHM Global Capability Owner. IBM Almaden Institute, San Jose 7 th May 2008.
5 Steps to Heaven – A Rolls-Royce Perspective

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Slide 1

5 Steps to Heaven – A Rolls-Royce Perspective

Dr Ian K Jennions

EHM Global Capability Owner

IBM Almaden Institute, San Jose7th May 2008

©2008 Rolls-Royce plcThe information in this document is the property of Rolls-Royce plc and may not be copied or communicated to a third party, or used for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce plc.

This information is given in good faith based upon the latest information available to Rolls-Royce plc, no warranty or representation is given concerning such information, which must not be taken as establishing any contractual or other commitment binding upon Rolls-Royce plc or any of its subsidiary or associated companies.

Slide 2

5 Steps to Heaven – A Rolls-Royce Perspective

Business Landscape

5 Steps to Heaven

Simulation of Total Care

Value in Data

Introduction

Our Service Business

Asset Management

Technology Successes

Marine EHM (Equipment

Health Management)

AE3007 HP Vane

QUICK

Future

Current Issues

Summary

© 2008 Rolls-Royce plc

Slide 3

Rolls-Royce’s four markets

© 2008 Rolls-Royce plc

Slide 4

Rolls-Royce Group plc - 2007

© 2008 Rolls-Royce plc

Slide 5

Video: ‘New Thinking, Joined Up Thinking'

© 2008 Rolls-Royce plc

Slide 6

5 Steps to Heaven – A Rolls-Royce Perspective

Business Landscape

5 Steps to Heaven

Simulation of Total Care

Value in Data

Introduction

Our Service Business

Asset Management

Technology Successes

Marine EHM (Equipment

Health Management)

AE3007 HP Vane

QUICK

Future

Current Issues

Summary

© 2008 Rolls-Royce plc

Slide 7

Changing Customer Requirements

Traditional Support

  • Spare parts

  • Repair & overhaul

Extended Support

  • Partnered capability to cover complete weapon systems

  • Turn-key services

  • Non-propulsion related support solutions

Total Support

  • Complete, availability- based service. Can cover all off-aircraft, and some on-aircraft activity

  • Configuration management & reliability enhancements covered

Reactive Aligned Integrated

Customer Value

Advanced Support

  • Comprehensive package integrating elements of basic and enhanced support

  • Spares inclusive R&O contracts

Enhanced Support

  • Data & forecasting services

  • Technical & logistics support

  • Customer training

Increased Scope

© 2008 Rolls-Royce plc

Slide 8

Extended Support

Total Management

Total

Support

Engine Availability

Customer Risk Service Provider Risk

Advanced Support

Asset Management

Enhanced Support

Forecasting

Basic Support

Traditional

Stage 5

  • Future EHM

    • Unknown at this time, but could include Powerplant and/or platform health monitoring

Stage 4

Increasing Scope of Service Provision

  • Extended EHM

    • Piece part diagnostics

    • Prognostic capability

    • Networking of systems (BROADEN)

Stage 3

  • Total Care EHM

    • Data fusion – oil/performance/vibration

    • Integration with LCC & WSG tools

    • Advanced diagnostic

    • Dynamic performance model (COMPASS)

Stage 2

  • Advanced EHM

    • Lifing

    • Performance trending

    • Oil trending

    • Vibration trending

    • Improved life counting

    • Basic diagnostics

Stage 1

  • Basic EHM

    • Lifing – cyclic counts

    • Digital borescope

Customer Exploits Info. to Reduce Cost

RR Exploits Info. to Increase Cost Effectiveness of Product

Commodity Service

The EHM Transformation Staircase - Defence

© 2008 Rolls-Royce plc

Slide 9

Total Care Simulation - Example

  • Product Operation

    • aircraft, engine, airport, operations control

  • Product Behaviour

    • engine, module, part, virtual characteristic

  • Asset Management

    • parts, modules, dedicated & lease pool spare engines, operator interaction

  • Manufacturing & Supply

    • aircraft, engines, modules, parts

  • Transportation & Logistics

    • engines, modules, parts

  • Engine Repair, Overhaul & Test

    • capacity, capability, resourcing, availability

  • Component & Module Repair

© 2008 Rolls-Royce plc

Slide 10

Total Care Simulation- video

© 2008 Rolls-Royce plc

Slide 11

Customer

Service Data

LCC Modelling Toolkit

(WP3)

Designer

Knowledge

Desktop (WP1)

Product Designer

Customer

Integrated Products and Services (IPAS)

New (IPAS)

New (IPAS)

Key:

New (IPAS)

New (IPAS)

Existing

Existing

Knowledge flow

Service Engineers/Overhaul trained and

Service Engineers/Overhaul trained and

motivated to share knowledge with design.

motivated to share knowledge with design.

Service Engineer/

Service Engineer/

Tools, methods and processes available to

Tools, methods and processes available to

Overhaul Shop

Overhaul Shop

support data and knowledge capture

support data and knowledge capture

Service Data

Service Data

LCC Modelling Toolkit

(WP3)

Designer

Knowledge

Desktop

Designer

Knowledge

Desktop (WP1)

Product Designer

Product Designer

Service Provider

Service Provider

LCC Modelling Toolkit

Customer

Customer

Customer

Customer

Designer able to search easily for

Designer able to search easily for

knowledge via intuitive interface,

knowledge via intuitive interface,

ontology models and social

ontology models and social

Social Issues and Solutions

solutions. Able to do LCC trade

solutions. Able to do LCC trade

-

-

Social Issues and Solutions

(WP1)

offs, understands service needs

offs, understands service needs

Product designed to support the service offering

Product designed to support the service offering

existing service knowledge base fully used,

existing service knowledge base fully used,

continuous improvement via optimized IPAS

continuous improvement via optimized IPAS

Processes

Processes

Optimised IPAS Processes

© 2008 Rolls-Royce plc

Slide 12

ETC

New

Doc

Legacy

Data

Source

2

Legacy

Doc

New

Data

Source

4

The IPAS System Architecture

Knowledge

Desktop

Knowledge

K-Search

Ontologies

Parts

Features

SAP

SDM

RCP

Reports

Other

Information

Mechanisms

Materials

Data Types

K-Forms

K-Forms

Data

Web

Services

© 2008 Rolls-Royce plc

Slide 13

IPAS Results – the ability to search legacy data

  • Legacy data is largely unstructured and is captured and stored in a variety of ways.

  • Development of ontologies for hardware description, failure mechanism etc. allow us to make sense of unstructured legacy data.

  • K-Search provides a means of interrogating legacy data and presenting structured search results back to the user

  • K-Search is a learning system that builds an understanding of document content such that after the ‘learning process’ >95% rate of correct automated document content classification can be achieved.

Automatically extracting knowledge from legacy unstructured data

© 2008 Rolls-Royce plc

Slide 14

5 Steps to Heaven – A Rolls-Royce Perspective

Business Landscape

5 Steps to Heaven

Simulation of Total Care

Value in Data

Introduction

Our Service Business

Asset Management

Technology Successes

Marine EHM (Equipment

Health Management)

AE3007 HP Vane

QUICK

Future

Current Issues

Summary

© 2008 Rolls-Royce plc

Slide 15

Marine Off-shore Supply and Service Vessel

Propulsion units monitored:

  • 4 Bergen 6 cylinder C engines.

  • 2 Azipull thrusters.

  • 2 Tunnel thrusters.

  • 1 swing up thruster.

© 2008 Rolls-Royce plc

Slide 16

Vessel 49 EHM Network Installation.

RRM

Service Centre

RRM

Ship network

EHM

Central unit

Propulsion

EHM unit

Engines

EHM unit

Engines

Data Coll. unit

Thrusters

EHM unit

Ethernet

© 2008 Rolls-Royce plc

Slide 17

AE3007 HPT Vane Distress

  • Leading edge burns away over time

  • Causes: cooling blockage, oxidation

  • Condition that typically occurs on high time engines (primarily on-condition engines)

  • Causes increased stress on the 1st stage blade leading to high cycle fatigue (secondary damage)

  • Turbine blade fracture leads to in flight shut down and a 2x shop visit cost

© 2008 Rolls-Royce plc

Slide 18

AE3007 HPT Vane Distress

Vane distress showed up as performance changes.

  • Data fusion allows clear signature to be set

    • Fuel flow, turbine temp, pressure & speed

  • 50 hour window after detection with 96% confidence of preventing HPT blade failures

    • Allows time to schedule removal

    • Thresholds set to balance false positives and false negatives

    • Relatively small number of false alerts and false negatives

© 2008 Rolls-Royce plc

Slide 19

AE3007 HPT Vane Distress - Savings

  • The alternative of not having EHM for this issue

    • Allow HPT-1 blade failures

    • Pull engines in mod campaign

    • Implement a 50 hr boroscope inspection interval

  • 8 yr EHM Savings estimated at over $60M

    • Based on mod campaign or inspections both ($$$$)

    • Savings continue as engines age and experience vane distress

© 2008 Rolls-Royce plc

Slide 20

So What’s the Problem ?

  • With high-integrity systems such as jet engines, conventional fault detection methods have limited capability:

    • The most important examples (i.e. the abnormalities) are very rare

    • Some of the fault conditions may not have been seen before

    • Subtle pre-cursor events often exist prior to failure but these are rarely detected by employing conventional techniques.

  • Advances being made at RR via advanced computational and signal processing methods, specifically:

    • QUICK, learn a description of normality and test against it (OBS)

    • Crack detection and propagation (Cranfield University)

    • Knowledge Based Diagnostics (Sheffield University)

    • DAME (Universities of York, Leeds, Sheffield and Oxford)

© 2008 Rolls-Royce plc

Slide 21

Quantitative User friendly Intelligent Collection of Knowledge (QUICK)

  • QUICK is a system used for real time acquisition and intelligent analysis of vibration and performance data from gas turbine engines.

  • QUICK has been developed over a number of years between Oxford University, Oxford BioSignals and Rolls-Royce

    The innovation in the product lies in:

    • The use of Computational Intelligence to quantify features

    • Building models of normality

    • Fusion of data from disparate sources for engine diagnostics.

    • The system is exploitable in other fields (e.g. medical)

© 2008 Rolls-Royce plc

Slide 22

QUICK video: Innovation Award

© 2008 Rolls-Royce plc

Slide 23

Novelty Thresholds – Bayesian EVT

23

© 2008 Rolls-Royce plc

Slide 24

Example results – 826 tests

24

© 2008 Rolls-Royce plc

Slide 25

5 Steps to Heaven – A Rolls-Royce Perspective

Business Landscape

5 Steps to Heaven

Simulation of Total Care

Value in Data

Introduction

Our Service Business

Asset Management

Technology Successes

Marine EHM (Equipment

Health Management)

AE3007 HP Vane

QUICK

Future

Current Issues

Summary

© 2008 Rolls-Royce plc

Slide 26

Different perspectives – system boundaries

© 2008 Rolls-Royce plc

Slide 27

LOCAL PLATFORM

Often has to operate

deployed and autonomously,

and often has an ability to

self maintain. If the platform

is mobile, data

communications may be

limited

EHM Intelligence Dichotomy

  • Fleet centred view - the realisation of full value by having an accurate, real time fleet view of the state of all assets

  • Platform centric view - Devolving EHM intelligence to the local platform to compensate for:

    • limitations in communicating with a central information hub (a lack of infrastructure and capacity)

    • Requirements for assets to operate and be maintained autonomously

    • Concerns for data privacy and IPR

Communications

Some organizations

bandwidth may be

do not want to export

CENTRAL HUB

LOCAL PLATFORM

limited and may be

their data beyond

LOCAL PLATFORM

expensive

their firewalls

Processes EHM data

Often has to operate

centrally and issues

Often has to operate

deployed and autonomously,

alerts. Maintains an

deployed and autonomously,

Data Communications infrastructure

and often has an ability to

overview of the condition

and often has an ability to

self maintain. If the platform

of the full fleet. Is able to

self maintain ‘on mission’. If

is mobile, data

Real time monitoring offers advantages of

mitigate the operational

the platform is mobile, data

communications may be

better resolution, earlier detection and a

consequences of

communications channels

limited

wider scope of failure mode detection - at

failure

may change and be limited

the price of having to process much

higher data volumes

THE RESULT IS PRESSURE TO PUSH EHM INTELLIGENCE TOWARD THE PLATFORM

© 2008 Rolls-Royce plc

Slide 28

Service Data Manager

CoreControl

CoreAlert

Aero Exec Integrator

SAP

Gold (T45 Programme)

Vision: HUMS Information Fused with Operations for Optimised Fleet Management

© 2008 Rolls-Royce plc

Slide 29

Vision: The Operations Room of the Future?

Oil uplift and utilization

data transferred from Squadron and pilot reports

Repair and Overhaul

EHUMS data download from A/C

using data retrieval unit (DRU) routed via Ground Support System (GSS) to Operations Centre

AI fault recognition and diagnosis

All Operations linked through global GRID system

Customers can view status on DefenceManager

Operations Room - processes information

Agent-based aftermarket modelling and decision support

Customers alerted by pager, e-mail or cell phone

Service team monitors output and liases with customer

© 2008 Rolls-Royce plc

Slide 30

5 Steps to Heaven - Summary

  • In the OEM to Service business transformation data is key

  • Operating on the data to create information and knowledge has been demonstrated, including value, in a number of areas.

  • With risk shift from Customer to OEM in a Service model EHM is risk mitigation, informing the Aftermarket business and helping to minimise unplanned events

  • Basic EHM has been yielding good results for a number of years, the next steps are much more complicated

© 2008 Rolls-Royce plc

Slide 31

Cranfield Integrated Vehicle Health Management Centre of Excellence

  • Vision

  • A world-class research and demonstration Centre of Excellence, seeking to establish industry standards and yielding competitive advantages in Integrated Vehicle Health Management (IVHM) for its industry members.

  • Strategic Aims

  • Attract Investment – supplement launch funding by attracting additional investment from new core partners/members and research funding bodies

  • World Recognition – working with industry and academic leaders

  • Technology Transfer – implementation of concepts and technologies within the industry and develop the associated skills base

  • Self Sustaining – after 5 years

  • Delivery of Competitive Advantage – to the key stakeholders

Generic Architecture

CoE Concept

Funding/ Governance

  • http://www.cranfield.ac.uk/cua

© 2008 Rolls-Royce plc


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