Advanced Diagnostics of Position Sensors for the Actuation Systems of High-Speed Tilting Trains

Trains tilting permits a train to travel at a high speed while maintaining an acceptable passenger ride quality with respect to the lateral acceleration, and the consequent lateral force, received by the passengers when the train travels on a curved track at a speed in excess of the balance speed built into the curve geometry. The tilting of a train carbody is performed by a control and actuation system which operates as a closed servoloop accepting the commands from the train control system, generating the torque necessary to tilt the carbody with respect to the bogie and measuring the tilt angle to close the control loop. Measurement of the tilt angle of each train vehicle is performed by two sensors located in the front and rear part of the vehicle. Since a correct tilt angle measurement is vital for the system operation and for ensuring a safe ride, in case of discrepancy between the signals of the two tilt angle sensors of any vehicle, the tilting operation is disabled and the train speed is reduced. An innovative tilt angle sensors health management system is herein presented that makes intelligent use of all available information to allow detection of malfunctioning of an individual tilt angle sensor, thereby enabling a continued operation of the tilting system and a high speed travel after a sensor failure occurs

Prognostic and Health Management System for Fly-by-wire Electro-hydraulic Servo Actuators for Detection and Tracking of Actuator Faults ☆

Abstract Maintenance of flight control actuation systems is currently performed on a scheduled basis, however air fleet operators and component manufacturers are willing to move from scheduled maintenance to Condition Based Maintenance (CBM) in order to reduce maintenance costs and improve aircraft dispatchability. Prognostics and Health Management (PHM) systems are a critical part of CBM and are perceived as a breakthrough technology to effectively respond to an urgent and critical need to improve the readiness, availability, reliability, safety and maintainability of aerospace vehicles. This paper presents the results of an ongoing research activity focused on the development of a PHM system for fly-by-wire Electro-Hydraulic Servo Actuators (EHSA) without adding new sensors. The PHM system is being developed with the objective of detecting the most common faults, according to a failure mode effects and criticality analysis (FMECA). The paper describes in particular the tools used for detection and tracking of internal leakage faults of the hydraulic actuator, which is one of the most common faults of hydraulic servo-actuators in service, and for predicting its remaining useful life (RUL). The research work has been supported by the development of a nonlinear model for a reference EHSA, that has been implemented using physical equations and system parameters, taking into account environmental condition and disturbances. The model was validated through tests runs on a flight control actuator of a civil aircraft. Simulations are performed in nominal conditions and with progressive injection of degradation to verify the PHM algorithm. The performances of the PHM algorithms are evaluated by means of proper metrics

A powerful tool for automatic validation of a Modelica library for electromechanical actuation systems for primary flight controls

Validation process aims at verifying requirements, specifications and behaviour of the final product. The procedure, outlined in this paper, has been defined to assess the library developed during ACTUATION2015 research project whose components are focused on the simulation of electromechanical actuation systems applied to aeronautic field. Therefore the validation procedure is presented with references to the experience and knowledge acquired during that project. A Modelica based validation tool has been developed to automate the process and manage the components testing independently from their physical domain (e.g. Electrical, Mechanical, etc). The functions composing the validation library are discussed in the paper and significant examples are presented

A powerful tool for automatic validation of a Modelica library for electromechanical actuation systems for primary flight controls

Validation process aims at verifying requirements, specifications and behaviour of the final product. The procedure, outlined in this paper, has been defined to assess the library developed during ACTUATION2015 research project whose components are focused on the simulation of electromechanical actuation systems applied to aeronautic field. Therefore the validation procedure is presented with references to the experience and knowledge acquired during that project. A Modelica based validation tool has been developed to automate the process and manage the components testing independently from their physical domain (e.g. Electrical, Mechanical, etc). The functions composing the validation library are discussed in the paper and significant examples are presented

Design of a PHM system for electro-mechanical flight controls: a roadmap from preliminary analyses to iron-bird validation

Literature on PHM is focused on research dedicated to the definition of new algorithms to achieve better failures prognosis or earlier and more accurate fault diagnosis, but lacks of examples on the design of novel PHM frameworks and the practical issues related with their implementation. This paper describes a roadmap for the design of a novel Prognostics and Health Management system while making reference to a real-case scenario applied to electro-mechanical actuators for flight control systems

Preliminary study towards the definition of a PHM framework for the hydraulic system of a fly-by-wire helicopter

On-board hydraulic systems are tasked to provide a number of critical functions to ensure the in-flight operability of rotary-wings vehicles; the hydraulic system is needed to supply power to the flight control actuators and a number of other utilities, as well as to condition the hydraulic fluid, under a wide range of possible in-service conditions. Being a flight-critical system, the definition of a Prognostics and Health Management framework would provide significant advantages to the users, such as better risk mitigation and improved availability. Moreover, a significant reduction in the occurrences of unpredicted failures, one of the more known downsides of helicopters, is expected. A preliminary analysis on the effects of the inception and progression of several degradation types is the first step assess the feasibility of a PHM system for new platforms, and which failure modes are more likely to be observed. Further, since several key components are frequently provided by different suppliers to the airframer, this preliminary analysis would allow to better assess if an Integrated Vehicle Health Management approach, integrating signals coming from different components, could be beneficial. To pursue this study, a complete model of the hydraulic system for a flyby-wire helicopter has been prepared. Then, an in-depth simulation campaign was pursued with the aim of studying the interactions between different failure modes, the effects that the propagating degradations have on the system performances and which signals can be used to define a robust set of features. The paper introduces the case-study under analysis, a general configuration for fly-by-wire helicopters, presenting the most prominent peculiarities of the system and the effect of such peculiarities on the definition of health monitoring schemes. The model is then used to describe the behavior of the system under nominal and degraded conditions is introduced. Between the possible failure modes, the interaction between wear in several mechanical components and the clogging of the hydraulic lines filters was chosen as the subject of this study; motivations are provided and the degradation model described in detail. Hence, results of a wide-ranging simulation campaign are presented, where the time-domain response of the system is used to guide in the definition of a proper set of features able to characterize the selected fault cases. Selected features are presented, chosen according to significant metrics such as correlation with the simulated degradations, signal-to-noise ratio and accuracy. Two different approaches with a varying degree of integration between system signals are proposed and compared. Prognostics is then pursued through well-known particle filter algorithms. The analysis provides promising results on the capability of successfully detecting, isolating and identifying the selected fault mode; laying the foundations for further and more comprehensive studies on the subject

Hydraulic Actuation System with Active Control for the Lateral Suspensions of High Speed Trains

High speed trains normally use actively controlled pneumatic systems to recenter the carbody with respect to the bogie when the train negotiates a curve. Pneumatic systems are used because of their softness, which adds a little contribution to the elastic force generated by the mechanical springs of the lateral suspension system, thereby allowing the neccessary dynamic isolation between carbody and bogie. Howeve, pneumatic systems have the drawbacks of large dimensions and slow response, often accompanied by a few damped oscillations. An innovative solution was developed which makes use of hydraulic actuators providing them with artificial compliance generated by an appropriate control, hence making hydraulic actuators suitable for this application. A carbody centering system is thus obtained presenting fast response, small volume and a softness comparable to that of a pneumatic system. The optimal control law for this system was defined, the system dynamic characteristics were analyzed and a technological demonstrator was built to assess the system merits. The paper outlines the theoretical grounds for the system control, its performance and the most significant results obtained during a test campaign conducted on the technological demonstrator

Multivariate Processing of Accelerometric Condition Indicators

An innovative integrated self-learning health monitoring system has been developed and implemented on a fleet of helicopters in actual service. This system improves significantly the efficiency of a previous accelerometric vibrational monitoring tool by means of multivariate third level processing of the accelerometric features. The paper describes the way in which several problems, typical for the monitoring process of a mechanical system, have been treated in this specific case. The applied techniques could be of much more general interest

A Robust Adaptive Hydraulic Power Generation System for Jet Engines

The paper presents an innovative hydraulic power generation system able to enhance performance, reliability and survivability of hydraulic systems used in military jet engines, as well as to allow a valuable power saving. This is obtained by a hydraulic power generation system architecture that uses variable pressure, smart control, emergency power source and suitable health management procedures. A key issue is to obtain all these functions while reducing to a minimum the number of additional components with respect to the conventional hydraulic power generation systems. The paper firstly presents the state-of-art of these systems and their critical issues, outlines the alternative solutions, and then describes architecture, characteristics and performance of the hydraulic power generation system that was eventually defined as a result of a research activity aimed at moving beyond the present state-of-art in this fiel