CERES :: Browsing by Author "Ali, Fakhre"

Browsing by Author "Ali, Fakhre"

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Open Access
Acoustic monitoring of an aircraft auxiliary power unit
(Elsevier, 2023-01-13) Ahmed, Umair; Ali, Fakhre; Jennions, Ian
In this paper, the development and implementation of a novel approach for fault detection of an aircraft auxiliary power unit (APU) has been demonstrated. The developed approach aims to target the proactive identification of faults, in order to streamline the required maintenance and maximize the aircraft’s operational availability. The existing techniques rely heavily on the installation of multiple types of intrusive sensors throughout the APU and therefore present a limited potential for deployment on an actual aircraft due to space constraints, accessibility issues as well as associated development and certification requirements. To overcome these challenges, an innovative approach based on non-intrusive sensors i.e., microphones in conjunction with appropriate feature extraction, classification, and regression techniques, has been successfully demonstrated for online fault detection of an APU. The overall approach has been implemented and validated based on the experimental test data acquired from Cranfield University’s Boeing 737-400 aircraft, including the quantification of sensor location sensitivities on the efficacy of the acquired models. The findings of the overall analysis suggest that the acoustic-based models can accurately enable near real-time detection of faulty conditions i.e., Inlet Guide Vane malfunction, reduced mass flows through the Load Compressor and Bleed Valve malfunction, using only two microphones installed in the periphery of the APU. This study constitutes an enabling technology for robust, cost-effective, and efficient in-situ monitoring of an aircraft APU and potentially other associated thermal systems i.e., environmental control system, fuel system, and engines.
Open Access
Aircraft system-level diagnosis with emphasis on maintenance decisions
(SAGE, 2021-10-26) Skliros, Christos; Ali, Fakhre; King, Steve; Jennions, Ian
This paper proposes a diagnostic technique that can predict component degradation for a number of complex systems. It improves and clarifies the capabilities of a previously proposed diagnostic approach, by identifying the degradation severity of the examined components, and uses a 3D Principal Component Analysis approach to provide an explanation for the observed diagnostic accuracy. The diagnostic results are then used, in a systematic way, to influence maintenance decisions. Having been developed for the Auxiliary Power Unit (APU), the flexibility and power of the diagnostic methodology is shown by applying it to a completely new system, the Environmental Control System (ECS). A major conclusion of this work is that the proposed diagnostic approach is able to correctly predict the health state of two aircraft systems, and potentially many more, even in cases where different fault combinations result in similar fault patterns. Based on the engineering simulation approach verified here, a diagnostic methodology suitable from aircraft conception to retirement is proposed.
Open Access
Assessment of heat exchanger degradation in a Boeing 737-800 environmental control system
(ASME, 2021-04-02) Jennions, Ian; Ali, Fakhre
There are a number of systems on an aircraft working together, in harmony, to produce safe and trouble free flight. The Environmental Control System (ECS) is one of these systems, and its failure is a major contributor to unscheduled maintenance, particularly in older aircraft. The ECS is composed of several complex sub-systems and components, but at its heart is the passenger air conditioner (PACK). The PACK is prone to degradation, which can lead to the functional failure of the ECS. Often its degradation is masked by the overall ECS control system and this can, ultimately, result in the ECS shutting down and extensive maintenance being required. There are a number of critical fault modes associated with the PACK, and in this paper those modes associated with the primary and secondary heat exchangers are explored. A robust ECS simulation framework called SESAC (Simscape ECS Simulation under All Conditions) has previously been implemented, calibrated, and tested, against data from healthy systems. Here the simulations are extended to cover degraded components in a representative Boeing 737-800 aircraft PACK model. Fault modes such as blockage and fouling are assessed for the primary and secondary heat exchangers of the PACK. Simulation results, in terms of temperature, pressure and mass flow at various degradation severities, are presented and discussed. The results highlight the interdependency between the PACK components, and the strong association between the primary and secondary heat exchanger performance.
Open Access
Boeing 737-400 passenger air conditioner control system model for accurate fault simulation
(American Society of Mechanical Engineers, 2022-03-08) Chowdhury, Shafayat H.; Ali, Fakhre; Jennions, Ian K.
The aircraft environmental control system (ECS) is a highly integrated and complex system. The passenger air conditioner (PACK) is the heart of the ECS and has been reported as a key driver of unscheduled maintenance by aircraft operators. This is principally due to the PACK’s ability to compensate for degraded components, and hence mask their real condition, so that when failure occurs it is a major event. The development of an accurate diagnostic solution would identify the degradation early and hence focus effective maintenance and reduce cost. This paper is a continuation of the authors’ work on the development of a systematically derived PACK simulation for accurate fault diagnostics, utilizing a model-based approach. In practice, the PACK simulation accuracy is dependent on a number of factors, which include the understanding of its control system. The paper addresses this by taking an in-depth look at the factors controlling the operation of the PACK to enable the gap between the theoretical understanding of the PACK and the engineering design of the system to be bridged, and accurate simulations under healthy and degraded scenarios obtained. This paper provides a comprehensive explanation of the PACK control system elements (principally valves) and verifies their operation based on experimental test data acquired from a B737-400 aircraft. A discussion of the control used in the simulation is then given, resulting in the correct temperature, pressure, and flow being delivered to the cabin. The overall simulation results are then presented to demonstrate the importance of using a systematically derived control logic. They are then further used to assess the impact of degradation in the main PACK valves (PVs).
Open Access
CFD investigation of a core-mounted-target-type thrust reverser, Part 1: reverser stowed configuration
(ASME, 2017-12-25) Mahmood, Tashfeen; Jackson, Anthony J. B.; Sethi, Vishal; Khanal, Bidur; Ali, Fakhre
During the second half of the 90's, NASA performed experimental investigations on six novel Thrust Reverser designs; Core Mounted Target Type Thrust Reverser (CMTTTR) design is one of them. To assess the CMTTTR efficiency and performance, NASA conducted several wind tunnel tests at Sea Level Static conditions. The results from these experiments are used in this paper series to validate the CFD results. This paper is part one of the three-part series; Part 1 and 2 discusses the CMTTTR in stowed and deployed configurations, all analysis in the first two papers are performed at SLS conditions. Part3 discusses the CMTTTR in the forward flight condition. The key objectives of this paper are: first, to perform the 3D CFD analysis of the reverser in stowed configuration; all analyses are performed at SLS condition. The second objective is to validate the acquired CFD results against the experimental data provided by NASA[1]. The third objective is to verify the fan and overall engine net thrust values acquired from the aforementioned CFD analyses against those derived based on 1-D engine performance simulations. The fourth and final objective is to examine and discuss the overall flow physics associated with the CMTTTR under stowed configuration. To support the successful implementation of the overall investigation, full-scale 3DCAD models are created, representing a fully integrated GE90 engine, B777 wing, and pylon configuration. Overall a good agreement is found between the CFD and test results; the difference between the two was less than 5%.
Open Access
Development of a far-field noise estimation model for an aircraft auxiliary power unit
(IEEE, 2021-09-14) Ahmed, Umair; Ali, Fakhre; Jennions, Ian K.
Aircraft Auxiliary Power Unit (APU) is one of the major aircraft systems and is reported to be a key driver of unscheduled maintenance. So far, the research has been focused on the implementation of the APU thermodynamic state data to isolate and diagnose faults. To advance the available diagnostic techniques, research work has been initiated to explore the potential of employing far-field microphone data for the identification and isolation of APU faults. This paper aims to address the first step required in the overall effort and proposes a novel methodology for the development of a noise model that can be used for evaluating noise as a source of fault diagnostics. The methodology integrates experimentally acquired full-scale aircraft state and noise data, a physics-based APU thermodynamic model, and semi-empirical noise models to estimate the noise produced by an aircraft APU based on a limited parameter-set. The methodology leads to a model which works by estimating the unknown thermodynamic parameters from the limited dataset and then passes on the relevant parameters to noise estimation models (combustion/jet noise models). An inherent part of the model is the effect of multipath propagation and ground reflections for which a relationship has been analytically derived that considers all the necessary parameters. The developed model has been validated against experimental noise and thermodynamic data acquired from a Boeing 737-400 aircraft APU under several different operating conditions. The acquired noise estimates suggest that the proposed approach provides an accurate estimation of the far-field noise under a wide range of APU operating conditions, both at the sub-system and APU level. The model would act as an enabler to simulate APU noise data under degraded functional states and subsequently developing fault diagnostic schemes based on the far-field noise data.
Open Access
Development of a novel ground test facility for aircraft environmental control system
(American Society of Mechanical Engineers, 2023-06-12) Chowdhury, Shafayat Hasan; Ali, Fakhre; Jennions, Ian K.
In this article, the development and experimental investigation of a Boeing 737 aircraft environmental control system (ECS) passenger air conditioner (PACK) has been reported. The PACK is the heart of the ECS that conditions bleed air prior to supplying it to the cabin and avionics bay. Its capability to mask fault occurrences has resulted in increased unscheduled maintenance of the system. As such it has been a key research topic to understand PACK performance characteristics in order to support an accurate diagnostic solution. This article is a continuation of the authors’ work on the development of a systematically derived PACK simulation model and reports the overall development and qualification of a novel in situ ground test facility (GTF) for the experimental investigation of a B737-400 aircraft PACK under various operating modes, including the effect of trim air system. The developed GTF enables the acquisition of the temperature, pressure, and mass flow data throughout the PACK. The overall process of instrumentation selection, installation, sensor uncertainty, and testing in terms of data repeatability and consistency has been reported. The acquired data are then employed to conduct verification and validation of the SESAC (simscape ECS simulation under all conditions) simulation framework. The reported research work therefore enables the advancement in the level of scientific understanding corresponding to the ECS PACK operation under real operating conditions, and therefore supports the development of a robust simulation framework for ECS fault diagnostics at the system level.
Open Access
Evaluation of aircraft auxiliary power unit near-field acoustics for condition monitoring
(IEEE, 2022-10-10) Ahmed, Umair; Ali, Fakhre; Jennions, Ian K.
This paper presents a comprehensive evaluation of the near-field acoustics of an aircraft auxiliary power unit (APU), based on experimental data acquired from an in-situ APU. The aim is to establish whether near-field acoustics can be implemented for online condition monitoring. The APU of Cranfield University’s demonstrator aircraft, a Boeing 737-400, has been instrumented to acquire acoustics (near-field and far-field) and vibration data in synchronization with aircraft state parameters under a wide range of operating conditions. The acquired data is first implemented to determine the efficacy of employing near-field / far-field microphones, and vibration sensors, to monitor the combustion noise and tonal frequency levels from the APU components. Subsequently, an evaluation of the broadband characteristics of the vibroacoustic data and its variations against APU states and performance parameters is conducted based on several categories of feature extraction techniques. The findings suggest that nearfield acoustics lacks the ability to capture the combustion noise process. In addition, the tonal frequencies are also lost due to the level of background noise, fluctuations in the APU speeds, and scattering effects. For the same reasons, the phase couplings occurring between the signals generated by the APU components cannot be detected using acoustic data. Nevertheless, the overall analysis substantiates that the near-field acoustic data can be used to predict the APU operating states and has the potential to be implemented for developing APU performance parameter estimation models to enable condition monitoring.
Open Access
Evaluation of component level degradation in the Boeing 737-800 air cycle machine
(American Society of Mechanical Engineers, 2022-12-19) Jennions, Ian; Ali, Fakhre
An aircraft is composed of several highly integrated and complex systems that enable it to deliver safe and comfortable flight. Its functionality is therefore strongly dependent on the safe operation of these systems within their designed optimal efficiencies. The air cycle machine (ACM) is a subsystem of the pressurized air conditioner (PACK) system, its key function is to enable refrigeration of the air in order to comply with the wide range of cabin environment requirements for maintaining aircraft safety and passenger comfort. The operation of the ACM is governed by the PACK control system which can mask degradation in its component during operation until severe degradation or failure results. The required maintenance is then both costly and disruptive. The ACM has been reported as one of the most frequently replaced subsystem and has been therefore reported as a major driver of unscheduled maintenance by the operators. This paper aims to investigate the component level degradation in the ACM at various severities and quantify the impact of its performance characteristics and associated interdependencies at PACK system level. In this paper, Cranfield University’s in-house environmental control system (ECS) simulation framework called simscape ECS simulation under all conditions (SESAC) has been implemented to evaluate degradation in the ACM components in a representative Boeing 737-800 aircraft PACK model. The fault modes of interest are those highlighted by the operators and correspond to the ACM compressor, turbine, and interconnecting mechanical shaft efficiency degradation. Simulation results, in terms of temperature, pressure, and mass flow at various degradation severities, are presented and discussed for each component at PACK system level. The acquired results suggest that, for all three fault modes, the PACK controller can compensate for an ACM degradation severity of up to 20%, allowing the PACK to sustain the delivery of the demanded temperature and mass flow. For degradation severity of above 20%, the PACK is able to deliver the demanded temperature with a substantially reduced mass flow. This has a significant impact on the PACK’s ability to meet the cabin demand efficiently. The methodology reported and the findings conceived to serve as an enabler toward formulating an effective PACK fault diagnostics and condition monitoring solution at system level, and fault reasoning at vehicle level.
Open Access
Fault simulations and diagnostics for a Boeing 747 Auxiliary Power Unit
(Elsevier, 2021-07-01) Skliros, Christos; Ali, Fakhre; Jennions, Ian
Health monitoring of aircraft systems is of great interest to aircraft manufacturers and operators because it minimises the aircraft downtime (due to avoiding unscheduled maintenance), which in turn reduces the operating costs. The work that is presented in this paper explores, for a Boeing 747 APU, fault simulation and diagnostics for single and multiple component faults. Data that corresponds to healthy and faulty conditions is generated by a calibrated simulation model, and a set of performance parameters (symptom vector) are selected to characterise the components health state. For each component under examination, a classification algorithm is used to identify its health state (healthy or faulty) and the training strategy that is used considers the existence of multiple faults in the system. The proposed diagnostic technique is tested against single and multiple fault cases and shows good results for the compressor, turbine, Load Control Valve (LCV) and Fuel Metering Valve (FMV), even though these faults present similar fault patterns. On the contrary, the classifiers for the Speed Sensor (SS) and the generator do not provide reliable predictions. As regards the SS, the sensitivity assessment for this component showed that the existence of faults in the other components can sometimes mask the SS fault. The reason that the generator diagnosis fails under the proposed diagnostic technique is attributed to the fact that it has only a very slight influence on the other symptom vector parameters. In both cases, additional diagnostic strategies are suggested.
Open Access
Improvements in the rotorcraft fuel economy and environmental impact through multiple-landing mission strategy
(American Helicopter Society, 2016-05) Ali, Fakhre; Goulos, Ioannis; Pachidis, Vassilios
This paper presents an integrated rotorcraft multidisciplinary simulation framework, deployed for the comprehensive assessment of combined rotorcraft–powerplant systems performance at mission level. The proposed methodology comprises a wide-range of individual modelling theories applicable to rotorcraft performance and flight dynamics, gas turbine engine performance, and estimation of gaseous emissions (i.e. nitrogen oxides, NOx). The overall methodology has been deployed to conduct a comprehensive mission level feasibility study for a twin-engine light (TEL) rotorcraft, modeled after the Airbus Helicopters Bo105 configuration operating on a multiple-landing flying (MLF) mission approach compared to rotorcraft employing a conventional flying (CF) mission approach. The results of the analyses allow mission level assessment of the both aforementioned approaches for a wide-range of useful payload (UPL) values, mission range as well as mission level outputs (e.g. fuel burn, mission time, and gaseous emissions i.e. NOx). Furthermore, evaluation of engine cycle parameters (i.e. overall pressure ratio (OPR), turbine entry temperature (TET), and engine mass flow) are also carried out with respect to both approaches. The results acquired through the parametric analyses suggest that the MLF mission approach has the potential to significantly reduce rotorcraft mission fuel burn as well as gaseous emission (i.e. NOx). It has also been established through the acquired results that rotorcraft employing the MLF mission approach requires lower engine operating power throughout the entire mission duration, and therefore operates on a relatively lower engine OPR, combustor entry temperature, mass flow, rotational speed, and the TET compared to rotorcraft employing CF mission approach. It is emphasized that such operation of the engine can potentially improve the rate at which the engine components (i.e. compressor, combustor, and turbine) may deteriorate, thus the MLF mission approach can potentially provide further benefit in terms of engine maintenance and overall engine life. Finally it has been emphasised that the mission total range is a critical parameter in determining the level of benefit that can be attained from the employment of MLF mission approach.
Open Access
An integrated methodology to assess the operational and environmental performance of a conceptual regenerative helicopter
(Cambridge University Press, 2015-01-31) Ali, Fakhre; Goulos, Ioannis; Pachidis, Vassilios
This paper aims to present an integrated multidisciplinary simulation framework, deployed for the comprehensive assessment of combined helicopter powerplant systems at mission level. Analytical evaluations of existing and conceptual regenerative engine designs are carried out in terms of operational performance and environmental impact. The proposed methodology comprises a wide-range of individual modeling theories applicable to helicopter flight dynamics, gas turbine engine performance as well as a novel, physics-based, stirred reactor model for the rapid estimation of various helicopter emissions species. The overall methodology has been deployed to conduct a preliminary trade-off study for a reference simple cycle and conceptual regenerative twin-engine light helicopter, modeled after the Airbus Helicopters Bo105 configuration, simulated under the representative mission scenarios. Extensive comparisons are carried out and presented for the aforementioned helicopters at both engine and mission level, along with general flight performance charts including the payload-range diagram. The acquired results from the design trade-off study suggest that the conceptual regenerative helicopter can offer significant improvement in the payload-range capability, while simultaneously maintaining the required airworthiness requirements. Furthermore, it has been quantified through the implementation of a representative case study that, while the regenerative configuration can enhance the mission range and payload capabilities of the helicopter, it may have a detrimental effect on the mission emissions inventory, specifically for NOx (Nitrogen Oxides). This may impose a trade-off between the fuel economy and environmental performance of the helicopter. The proposed methodology can effectively be regarded as an enabling technology for the comprehensive assessment of conventional and conceptual helicopter powerplant systems, in terms of operational performance and environmental impact as well as towards the quantification of their associated trade-offs at mission level. Ali Fakhre, Ioannis Goulos, Vassilios Pachidis School of Engineering, Energy, Power and Propulsion Division, Cranfield University, Cranfield, Bedford, MK43 0AL, UK f.ali@cranfield.ac.uk The Aeronautical Journal, 2015, Vol 119, Issue 1211, pp1-24 Published by Cambridge University Press. This is the Author Accepted Manuscript. This article may be used for personal use only. The final published version (version of record) is available online at 10.1017/S0001924000010253. Please refer to any applicable publisher terms of use.
Open Access
Multi-objective optimization of a regenerative rotorcraft powerplant: quantification of overall engine weight and fuel economy
(American Helicopter Society (AHS), 2015-07-30) Ali, Fakhre; Tzanidakis, Konstantinos; Goulos, Ioannis; Pachidis, Vassilios; d'Ippolito, Roberto
A computationally efficient and cost effective simulation framework has been implemented to perform design space exploration and multi-objective optimization for an advanced regenerative rotorcraft powerplant configuration at mission level. The proposed framework is developed by coupling a comprehensive rotorcraft mission analysis code with a design space exploration and optimization package. The overall approach is deployed to design and optimize the powerplant of a reference twin-engine light rotorcraft, modelled after the Bo105 helicopter, manufactured by Airbus Helicopters. Firstly, a sensitivity analysis of the regenerative engine is carried out to quantify the interrelationship between the engine thermodynamic cycle design parameters, engine weight, and overall mission fuel economy. Secondly, through the execution of a multi-objective optimization strategy, a Pareto front surface is constructed, quantifying the optimum trade-off between the fuel economy offered by a regenerative engine and the associated weight penalty. The optimum sets of cycle design parameters obtained from the structured Pareto front suggest that the employed heat exchanger effectiveness is the key design parameter affecting the engine weight and fuel efficiency. Furthermore, through quantification of the benefits suggested by the acquired Pareto front, it is shown that, the fuel economy offered by the simple cycle rotorcraft engine can be substantially improved with the implementation of regeneration technology, without degrading the payload-range and airworthiness (One- Engine-Inoperative) requirements of the rotorcraft.
Open Access
A review of aircraft auxiliary power unit faults, diagnostics and acoustic measurem
(Elsevier, 2021-04-30) Ahmed, Umair; Ali, Fakhre; Jennions, Ian
The Auxiliary Power Unit (APU) is an integral part of an aircraft, providing electrical and pneumatic power to various on-board sub-systems. APU failure results in delay or cancellation of a flight, accompanied by the imposition of hefty fines from the regional authorities. Such inadvertent situations can be avoided by continuously monitoring the health of the system and reporting any incipient fault to the MRO (Maintenance Repair and Overhaul) organization. Generally, enablers for such health monitoring techniques are embedded during a product's design. However, a situation may arise where only the critical components are regularly monitored, and their status presented to the operator. In such cases, efforts can be made during service to incorporate additional health monitoring features using the already installed sensing mechanisms supplemented by maintenance data or by instrumenting the system with appropriate sensors. Due to the inherently critical nature of aircraft systems, it is necessary that instrumentation does not interfere with a system's performance and does not pose any safety concerns. One such method is to install non-intrusive vibroacoustic sensors such that the system integrity is maintained while maximizing system fault diagnostic knowledge. To start such an approach, an in-depth literature survey is necessary as this has not been previously reported in a consolidated manner. Therefore, this paper concentrates on auxiliary power units, their failure modes, maintenance strategies, fault diagnostic methodologies, and their acoustic signature. The recent trend in APU design and requirements, and the need for innovative fault diagnostics techniques and acoustic measurements for future aircraft, have also been summarized. Finally, the paper will highlight the shortcomings found during the survey, the challenges, and prospects, of utilizing sound as a source of diagnostics for aircraft auxiliary power units.
Open Access
A review of aircraft environmental control system simulation and diagnostics
(SAGE, 2023-02-16) Chowdhury, Shafayat H.; Ali, Fakhre; Jennions, Ian K.
The aircraft Environmental Control System (ECS) enables the aircraft to maintain a comfortable and safe environment for its passengers throughout its operating envelope. The Pressurised Air Conditioner (PACK) is the heart of the ECS, and is composed of multiple sub-systems: heat exchangers, valves, compressor, turbine, and a water separator. The PACK’s principle function is to enable conditioning of the hot, high pressure bleed air from the engine or APU, for temperature, pressure and humidity against the cabin requirements. The operation of the PACK is governed by a control system which has the ability to mask degradation in its component during operation until severe degradation or failure results. The required maintenance is then both costly and disruptive. The PACK has been reported as major driver of unscheduled maintenance by the operators. The aviation industry is currently proactively exploring innovative health management solutions that aid the maintenance of aircraft key systems based on predictive based maintenance approaches using online condition monitoring techniques. This paper presents a comprehensive review of the simulation and diagnostic methodologies applicable to fault diagnostics of the ECS PACK. The existing literature suggests that model-based and data-driven methods are effective for conducting fault detection and isolation of the PACK system. The conceived findings indicate that the model-based diagnostic approach have been extensively employed to conduct PACK diagnostics at component level only. Their successful implementation requires robust experimental verification and validation against the actual data under healthy and faulty conditions. Although a substantial amount of work has been reported on developing first principles based simulation models and diagnostic strategies for the ECS, the acquired findings suggest that there is a compelling need for a verified and validated ECS simulation model to enable accurate PACK system-level diagnostics based on single and multiple component level degradation scenarios. It has also been identified that the existing literature lacks the evaluation of humidity regulation and the effect of the control system on the PACK performance characteristics. Finally, a taxonomy of diagnostic techniques and simulation models is compiled based on the available literature.
Open Access
A review of diagnostic methods for hydraulically powered flight control actuation systems
(MDPI, 2023-01-25) Iyaghigba, Samuel David; Ali, Fakhre; Jennions, Ian K.
Aircraft systems are designed to perform functions that will aid the various missions of the aircraft. Their performance, when subjected to an unfamiliar condition of operation, imposes stress on them. The system components experience degradation due to fault which ultimately results in failure. Maintenance and monitoring mechanisms are put in place to ensure these systems are readily available when required. Thus, the sensing of parameters assists in providing conditions under which healthy and faulty scenarios can be indicated. To obtain parameter values, sensor data is processed, and the results are displayed so that the presence of faults may be known. Some faults are intermittent and incipient in nature. These are not discovered easily and can only be known through a display of unusual system performance by error code indication. Therefore, the assessed faults are transmitted to a maintenance crew by error codes. The results may be fault found (FF), no fault found (NFF), or cannot display (CND). However, the main classification of the faults and their origins may not be known in the system. This continues throughout the life cycle of the system or equipment. This paper reviews the diagnostic methods used for the hydraulically powered flight control actuation system (HPFCAS) of an aircraft and its interaction with other aircraft systems. The complexities of the subsystem’s integration are discussed, and different subsystems are identified. Approaches used for the diagnostics of faults, such as model-based, statistical mapping and classification, the use of algorithms, as well as parity checks are reviewed. These are integrated vehicle health management (IVHM) tools for systems diagnostics. The review shows that when a system is made up of several subsystems on the aircraft with dissimilar functions, the probability of fault existing in the system increases, as the subsystems are interconnected for resource sharing, space, and weight savings. Additionally, this review demonstrates that data-driven approaches for the fault diagnostics of components are good. However, they require large amounts of data for feature extraction. For a system such as the HPFCAS, flight-management data or aircraft maintenance records hold information on performance, health monitoring, diagnostics, and time scales during operation. These are needed for analysis. Here, a knowledge of training algorithms is used to interpret different fault scenarios from the record. Thus, such specific data are not readily available for use in a data-driven approach, since manufacturers, producers, and the end users of the system components or equipment do not readily distribute these verifiable data. This makes it difficult to perform diagnostics using a data-driven approach. In conclusion, this paper exposes the areas of interest, which constitute opportunities and challenges in the diagnostics and health monitoring of flight-control actuation systems on aircraft.
Open Access
Signal processing of acoustic data for condition monitoring of an aircraft ignition system
(MDPI, 2022-09-19) Ahmed, Umair; Ali, Fakhre; Jennions, Ian
Degradation of the ignition system can result in startup failure in an aircraft’s auxiliary power unit. In this paper, a novel acoustics-based solution that can enable condition monitoring of an APU ignition system was proposed. In order to support the implementation of this research study, the experimental data set from Cranfield University’s Boeing 737-400 aircraft was utilized. The overall execution of the approach comprised background noise suppression, estimation of the spark repetition frequency and its fluctuation, spark event segmentation, and feature extraction, in order to monitor the state of the ignition system. The methodology successfully demonstrated the usefulness of the approach in terms of detecting inconsistencies in the behavior of the ignition exciter, as well as detecting trends in the degradation of spark acoustic characteristics. The identified features proved to be robust against non-stationary background noise, and were also found to be independent of the acoustic path between the igniter and microphone locations, qualifying an acoustics-based approach to be practically viable.
Open Access
Simulation of an aircraft environmental control system
(Elsevier, 2020-01-09) Jennions, Ian; Ali, Fakhre; Miguez, Manuel Esperon; Escobar, Ignacio Camacho
The environmental control system of a civil aircraft is a major driver of maintenance. Legacy systems, such as those on the Boeing 737, are particularly at risk, as they are not instrumented for health management. These systems degrade in operation and allow compensation within their operation for degrading components, until severe degradation or failure results. The required maintenance is then both costly and disruptive. The goal of this research is to produce a simulation environment that can model the aircraft environmental control system, in order that analysis for sensor placement and algorithms can be performed without extensive, and expensive, testing. A simulation framework called Simscape Environmental Control System Simulation under All Conditions has been proposed and implemented. It offers a library of components that can be assembled into specific aircraft environmental control system simulation configurations. It is capable of simulating the health state indicating parameters at sub-system and component levels under a wide-range of aircraft operating scenarios. The developed framework has been successfully implemented to simulate a Boeing 737-800 passenger air conditioner. Its verification and validation has been carried out against the actual data corresponding to a Boeing 737-800 passenger air conditioner operating at two different cruise operating points. An extensive comparison of the simulation is presented against the data for all the passenger air conditioner components. The overall acquired results suggest that changes in the aircraft ambient conditions can have a noticeable impact on the demanded passenger air conditioner outlet temperature, and a substantial impact on the heat transfer in the primary and secondary heat exchangers. The reported simulation capability serves as a first step towards formulating an environmental control system fault simulation and diagnostic solution.
Open Access
System diagnosis for an auxiliary power unit
(Cranfield University, 2020-08) Skliros, Christos; Jennions, Ian K.; Ali, Fakhre
Even though the Auxiliary Power Unit (APU) is a widely used system in modern aviation, the existing experimental, simulation and diagnostic studies for this system are very limited. The topic of this project is the System Diagnosis of an APU, and the case study that is used in this research is a Boeing 747 APU. This APU was used to develop an experimental rig in order to collect performance data under a wide range of loading and environmental conditions. The development of the experimental rig consumed considerable time and required the design and installation of structures and parts related with the control of the APU, the adjustment of the electric and pneumatic load and the data acquisition. The validation of the rig was achieved by a repeatability test, which ensures that the collected measurements are repeatable under the same boundary conditions, and by a consistency test, which ensures that the performance parameters are consistent with the imposed ambient conditions. The experimental data that are extracted from the rig were used to calibrate a physics-based (0-D) model for steady-state conditions. Data that correspond to faulty conditions were generated by injecting faults in the simulation model. Based on the most prominent APU faults, as reported by The Boeing Company, six components that belong to different sub-systems were considered in the diagnostic analysis, and for each one of them, a single fault mode was simulated. By using healthy and faulty simulation data, for each component under examination, a classification algorithm that can recognise the healthy and faulty state of the component is trained. A critical part of the diagnostic analysis is that each classifier was trained to recognise the healthy and the faulty state of the corresponding component, while other components can be either healthy or faulty. The test results showed that the proposed technique is able to diagnose both single and multiple faults, even though in many cases different component faults resulted in similar fault patterns.
Open Access
Understanding the role of sensor optimisation in complex systems
(MDPI, 2023-09-12) Suslu, Burak; Ali, Fakhre; Jennions, Ian K.
Complex systems involve monitoring, assessing, and predicting the health of various systems within an integrated vehicle health management (IVHM) system or a larger system. Health management applications rely on sensors that generate useful information about the health condition of the assets; thus, optimising the sensor network quality while considering specific constraints is the first step in assessing the condition of assets. The optimisation problem in sensor networks involves considering trade-offs between different performance metrics. This review paper provides a comprehensive guideline for practitioners in the field of sensor optimisation for complex systems. It introduces versatile multi-perspective cost functions for different aspects of sensor optimisation, including selection, placement, data processing and operation. A taxonomy and concept map of the field are defined as valuable navigation tools in this vast field. Optimisation techniques and quantification approaches of the cost functions are discussed, emphasising their adaptability to tailor to specific application requirements. As a pioneering contribution, all the relevant literature is gathered and classified here to further improve the understanding of optimal sensor networks from an information-gain perspective.