This application claims the benefit of Indian Provisional Application No. 202241006328 filed Feb. 7, 2022 for “DYNAMIC AIR DATA PROBE PROGNOSTICS HEALTH MONITORING EDGE DEVICE” by R. Balasubramanian and C. Roeske.
The disclosed subject matter relates generally to prognostics health monitoring, and more particularly, to a modular prognostics health monitoring system for air data probes.
Air data probes are safety-critical sensors installed on all modern aircraft to measure parameters like total pressure, static pressure, and in some cases, pressures for angle of attack and side slip. These probes are external to the aircraft and are exposed to harsh weather conditions and subzero temperatures. Such conditions may cause ice formation on part of the probe resulting in incorrect measurement of air data parameters. Accordingly, resistive heating elements are installed in the air data probes to prevent ice formation. To heat the probe, an operational voltage is provided through the heating element. Prolonged usage and frequent switching (i.e., between the OFF state and ON state) can lead to an abrupt failure of the heating element. When the heating element breaks down, the probe must be replaced prior to subsequent takeoff of the aircraft to ensure continued monitoring air data parameters. Thus, health monitoring of air data probes is critical.
Existing aircraft-based health monitoring systems can monitor various probe parameters but lack the sophistication to analyze the data using complex health monitoring algorithms. Data must be transmitted to a ground station for this purpose. Similarly, modification of the monitoring parameters in current systems requires the removal and reinstallation of the updated data acquisition module. A need exists for a dynamic health monitoring system for real-time prediction of remaining useful life and predicted failure of an air data probe with a high level of accuracy.
An edge device for use in a system for monitoring a vehicle-borne probe includes a first communication interface configured to receive sensed data related to a characteristic of a heating element of a first probe, a core application module configured to host a plurality of core applications, a dynamic application module configured to host a plurality of dynamic applications, and a processing unit configured to implement the plurality of core applications on the sensed data. The plurality of core applications includes a coarse data processing application configured to monitor and analyze the sensed data to generate a first data output.
A method for operating an edge device in a system for monitoring a vehicle-borne probe includes powering up the edge device, determining, by a processing unit of the edge device, a location and identification of the edge device, receiving, by a first communication interface of the edge device, sensed data related to a characteristic of a heating element of the probe, monitoring and analyzing, by a coarse data processing application of the edge device, the sensed data to generate a first data output, and sending, via a second communication interface of the edge device, the first data output to a coordinator.
While the above-identified figures set forth one or more embodiments of the present disclosure, other embodiments are also contemplated, as noted in the discussion. In all cases, this disclosure presents the invention by way of representation and not limitation. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art, which fall within the scope and spirit of the principles of the invention. The figures may not be drawn to scale, and applications and embodiments of the present invention may include features and components not specifically shown in the drawings.
This disclosure presents a prognostics health monitoring (PHM) system and method for estimating a remaining useful life (RUL) and predicting imminent failure of a vehicle-borne probe, such as an aircraft air data probe. The system includes one or more sensors in communication with each monitored probe. An edge device associated with a probe receives the sensed data and performs various levels of data analytics. Data outputs from each edge device are sent to a smart coordinator of the system for additional monitoring and analysis. The coordinator packages the data and sends it to a cloud infrastructure and ground station for detailed analysis.
Each probe 12 can be a pitot probe, total air temperature (TAT) probe, or angle-of-attack (AOA) probe, to name a few non-limiting examples, configured to measure aircraft operational parameters such as pressure and/or temperature. In an alternative embodiment, probes 12 can be mounted to other types of (non-aerial) vehicles and can be suitable for measuring operational parameters of such vehicles. Each probe 12 includes a resistive heating element 14, such as a heater wire, powered by a source of alternating (AC) or direct (DC) current. The flow of current through heating element 14 provides heating to the associated probe 12 to prevent ice accretion. The one or more sensors 16 in communication with a respective probe 12 can measure characteristics of an associated heating element 14, such as current, capacitance, and/or voltage.
Each sensor 16 outputs sensed heating element 14 data to an associated edge device 18.
In operation of system 10, data from sensor 16 is received by edge device 18 via a wired (e.g., Ethernet, AFDX, ARINC 429, RS232/422/485, CAN, etc.) or wireless (e.g., Bluetooth, Wi-Fi, cellular, etc.) first/input communication interface 48. The latter type of connection permits a sensor 16 and associated edge device 18 to be in physically separate locations on the aircraft. ADC 30 converts the received sensor 16 output signals to digital signals. Subsequent signal conditioning (e.g., filtering, linearization, amplification, etc.) is performed by signal conditioner 36. Power supply 38 can be any suitable source of power, such as a battery, energy harvesting devices, or other sources on the aircraft. Upon power-up of edge device 18, processing unit 40 reads device ID 32 and device location ID 34 to determine/confirm the type and physical location of edge device 18. Processing unit 40 then reads the device configuration stored in memory 42 and configures edge device 18 based on device ID 32 and location ID 34. Memory 42 can further store data and applications for access by processing unit 40. Processing unit 40 can be, for example, a microprocessor or microcontroller configured to perform various data processing and analysis tasks, discussed in greater detail below, and output processed data to coordinator 20 via second/output communication interface 48. Output communication interface 48 may be of the wired or wireless type discussed above with respect to input communication interface 48. Output communication interface 48 is configured to exchange data with coordinator 20. TPM 44 is at least one of various cybersecurity measures (e.g., certificate management, advanced encryption, etc.) implemented by edge device 18 for securely communicating with interfacing devices and systems.
Hosted PHM application module 58 can include core application module 60 with core applications 62-1, 62-2, and 62-3 (collectively referred to as “core applications 62”), and dynamic application module 64 with dynamic applications 66-1 and 66-2 (collectively referred to as “dynamic applications 66”). Various embodiments of edge device 18 can include any number of 1 to n core applications 62 and/or 0 to m dynamic applications 66. In some embodiments, core applications 62 and/or dynamic applications 66 can be incorporated into a field load bundle that enables updating of the hosted applications. The field load bundle can additionally and/or alternatively include any of the following sections for updating: device configuration information (e.g., edge device ID and location ID, serial number, part number, etc.), cybersecurity (e.g., certificates, encryption keys, etc.), device-specific software containing configuration information (e.g., input sample size, sampling rate, output rate, parameters, communication protocol, etc.), and software/firmware (e.g., executable object code, parameter data item, etc.).
Core applications 62 enable implementation of the PHM functions of edge device 18. More specifically, core application 62-1 can be an advanced local PHM data repository for implementing reusable data analytics algorithms (e.g., Fast Fourier Transform (FFT), arc fault detection, etc.) local to edge device 18. The various hosted PHM applications can use the algorithms implemented in the data analytics repository instead of duplicating their implementation. Core application 62-2 can be a stage-1 pre-PHM data processing application for continuously monitoring sensed heater 14 data, and for performing coarse-PHM data analytics on the sensed data using one or more coarse-PHM data analytics algorithms. Any resulting coarse data analytics outputs can be sent to coordinator 20, as well as further monitored by one of the dynamic applications 66, as is discussed in greater detail below. Core application 62-3 can be a field loader application for updating any of the bundled applications or sections discussed above.
Dynamic applications 66 are optional PHM applications that can be temporary or short-term in nature. More specifically, dynamic applications 66 can be automatically loaded onto edge device 18 by coordinator 20 and/or enabled/activated by the occurrence of one or more trigger events. As such, dynamic applications 66 can be automatically deactivated after a specific interval or when other conditions occur. Dynamic application 66-1 can include one or more application-specific monitoring algorithms (e.g., for brake temperature monitoring, acoustics monitoring, smart BIT, battery monitoring, vibration monitoring, cabin temperature monitoring, heater current arc fault detection, etc.). Dynamic application 66-2 can be a stage-2 targeted PHM assessment application for monitoring the coarse data outputs from the stage-1 pre-PHM application, performing finer data analysis on the monitored data, and dynamically updating the data monitoring scheme of the hosting edge device 18. The finer data analysis can include monitoring of additional parameters from the associated sensor 16, monitoring of parameters at a higher rate, and/or monitoring of higher parameters at higher precision and/or processing.
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Coordinator 20 can further synthesize monitored aircraft data from avionics system(s) 22 with the coarse data (stage-1) and finer data (stage-2) analytics outputs from multiple edge devices 18 for determining trigger events and making monitoring decisions. Accordingly, coordinator 20 can implement stage-3 PHM data analytics on the synthesized data.
At time t1, system 10 and the stage-1 and stage-2 applications from each edge device 18 are activated, and coordinator 20 begins monitoring edge device and aircraft data. At time t2, the stage-2 applications from each edge device 18 are activated for an interval defined generically as interval 68. The “start” trigger event for activation of the stage-2 applications is not plotted in
Data received and/or analyzed by coordinator 20 (e.g., aircraft data, stage-1, stage-2 and/or stage-3 data analytics outputs) can be timestamped and packaged before sending to cloud 26 and/or ground station 28. Cybersecurity measures, such as encryption and digital signatures, can be implemented by TPM 78 to ensure confidentiality, integrity, and authentication of the data package(s). In an alternative embodiment, system 10 can include more than one coordinator 20, and data packages can be shared among the multiple coordinators 20. Data packages are shared with cloud 26 and/or ground station 28 via on-aircraft gateway 24. Referring back to
Cloud 26 can implement a cloud-hosted PHM data analytics application for analyzing, using machine learning techniques, received PHM data to predict imminent failure and estimate RUL of air data probes 12.
Cloud 26 can further implement data storage for storing monitored data. Ground station 28 can access data stored in cloud 26 to perform additional analysis using, for example, advanced PHM algorithms, to further improve upon technologies and methods for estimating RUL and predicting imminent failures of probes 12. In some embodiments, ground station 28 can be configured to carry out the failure prediction and RUL estimation of method 100 in addition to, or as an alternative to cloud 26. This can be the case, for example, where it is desirable to provide redundancy, or where the functions of cloud 26 and ground station 28 overlap. RUL and failure predictions can be reported to a database monitored by and accessible to aircraft maintenance personnel. Such reporting can be accomplished via an alert or notification generated by an application of cloud 26, and/or by ground station 28. PHM system 10 allows for a tailored maintenance approach that allows for the timely replacement of faulty probes to minimize operational disruption and avoids the unnecessary replacement of healthy probes based on flight hours or other standard metrics.
The following are non-exclusive descriptions of possible embodiments of the present invention.
An edge device for use in a system for monitoring a vehicle-borne probe includes a first communication interface configured to receive sensed data related to a characteristic of a heating element of a first probe, a core application module configured to host a plurality of core applications, a dynamic application module configured to host a plurality of dynamic applications, and a processing unit configured to implement the plurality of core applications on the sensed data. The plurality of core applications includes a coarse data processing application configured to monitor and analyze the sensed data to generate a first data output.
The edge device of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:
In the above edge device, the plurality of core applications can further include: an advanced data repository for implementing reusable data analytics algorithms, and a field loader application configured to update at least one of device configuration files, cybersecurity certificate, device-specific software, and device-specific applications.
In any of the above edge devices, the plurality of dynamic applications can include a targeted assessment application configured to monitor and analyze the first data output.
In any of the above edge devices, the targeted assessment application can be pre-loaded in the edge device.
In any of the above edge devices, the targeted assessment application can be dynamically loaded in the edge device by a coordinator in communication with the edge device.
In any of the above edge devices, the targeted assessment application can be configured to generate a second data output.
Any of the above edge devices can further include: a memory accessible by the processing unit and configured to store the plurality of core applications, and a second communication interface configured to communicate the first data output and the second data output to a coordinator of the system.
In any of the above edge devices, the plurality of dynamic applications can further include: a monitoring application for monitoring at least one of brake temperature, acoustics, smart BIT, battery, vibration, cabin temperature, and heater current arc fault.
In any of the above edge devices, the characteristic of the heating element can be one of current, capacitance, and voltage.
In any of the above edge devices, the vehicle can be an aircraft, and the first probe can be one of a pitot probe, a total air temperature probe, and an angle-of-attack probe.
A system for monitoring a vehicle-borne probe includes a coordinator in communication with any of the above edge devices and configured to receive the first data output and the second data output from the first edge device and to incorporate the first data output and second data output into a data package, and a cloud infrastructure in communication with the coordinator via a data gateway and configured to analyze the data package to estimate a remaining useful life and predict a failure of the first probe.
In the above system, the coordinator can be in communication with the first edge device and the second edge device, and the coordinator can be configured to incorporate the first data output, the second data output, and a third data output from the second edge device into the data package.
A method for operating an edge device in a system for monitoring a vehicle-borne probe includes powering up the edge device, determining, by a processing unit of the edge device, a location and identification of the edge device, receiving, by a first communication interface of the edge device, sensed data related to a characteristic of a heating element of the probe, monitoring and analyzing, by a coarse data processing application of the edge device, the sensed data to generate a first data output, and sending, via a second communication interface of the edge device, the first data output to a coordinator.
The method of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:
The above method can further include: monitoring, by a targeted assessment application of the edge device, the first data output, and analyzing, by the targeted assessment application, the first data output and generating a second data output.
Any of the above methods can further include: loading and activating, by the coordinator, a targeted assessment application to the edge device, and analyzing the first data output if a trigger event occurs.
In any of the above methods, the trigger event can include a start event and an end event.
In any of the above methods, the start event can include at least one of a probe fault and exceedance of a parameter threshold or count.
In any of the above methods, the end event can include one of elapsing of a predetermined amount of time after the start event, and exceedance of a parameter threshold or count.
While the invention has been described with reference to an exemplary embodiment(s), it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment(s) disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.
Number | Date | Country | Kind |
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202241006328 | Feb 2022 | IN | national |