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Self-tuning aircraft engine models can be applied for control and health management applications. The self-tuning feature of these models minimizes the mismatch between any given engine and the underlying engineering model describing an engine family. This paper provides details of the construction of a self-tuning engine model centered on a piecewise linear Kalman filter design. Starting from a nonlinear transient aerothermal model, a piecewise linear representation is first extracted. The linearization procedure creates a database of trim vectors and state-space matrices that are subsequently scheduled for interpolation based on engine operating point. A series of steady-state Kalman gains can next be constructed from a reduced-order form of the piecewise linear model. Reduction of the piecewise linear model to an observable dimension with respect to available sensed engine measurements can be achieved using either a subset or an optimal linear combination of health parameters, which describe engine performance. The resulting piecewise linear Kalman filter is then implemented for faster-than-real-time processing of sensed engine measurements, generating outputs appropriate for trending engine performance, estimating both measured and unmeasured parameters for control purposes, and performing on-board gas-path fault diagnostics. Computational efficiency is achieved by designing multidimensional interpolation algorithms that exploit the shared scheduling of multiple trim vectors and system matrices. An example application illustrates the accuracy of a self-tuning piecewise linear Kalman filter model when applied to a nonlinear turbofan engine simulation. Additional discussions focus on the issue of transient response accuracy and the advantages of a piecewise linear Kalman filter in the context of validation and verification. The techniques described provide a framework for constructing efficient self-tuning aircraft engine models from complex nonlinear simulation, See also ADA581775. Annual Conference of the Prognostics and Health Management Society (PHM 2012) held in Minneapolis, Minnesota on September 23-27, 2012. Sponsored by the Office of Naval Research (ONR).

Receiver Operator Characteristic (ROC) curves are commonly applied as metrics for quantifying the performance of binary fault detection systems. An ROC curve provides a visual representation of a detection system's True Positive Rate versus False Positive Rate sensitivity as the detection threshold is varied. The area under the curve provides a measure of fault detection performance independent of the applied detection threshold. While the standard ROC curve is well suited for quantifying binary fault detection performance, it is not suitable for quantifying the classification performance of multi-fault classification problems. Furthermore, it does not provide a measure of diagnostic latency. To address these shortcomings, a novel three-dimensional receiver operator characteristic (3D ROC) surface metric has been developed. This is done by generating and applying two separate curves: the standard ROC curve reflecting fault detection performance, and a second curve reflecting fault classification performance. A third dimension, diagnostic latency, is added giving rise to three-dimensional ROC surfaces. Applying numerical integration techniques, the volumes under and between the surfaces are calculated to produce metrics of the diagnostic system's detection and classification performance. This paper will describe the 3D ROC surface metric in detail, and present an example of its application for quantifying the performance of aircraft engine gas path diagnostic methods. Metric limitations and potential enhancements are also discussed., See also ADA548241. Annual Conference of the Prognostics and Health Management Society (PHM 2010) Held in Portland, Oregon on October 10-14, 2010. U.S. Government or Federal Purpose Rights License., The original document contains color images.

Intelligent Control and Health Management technology for aircraft propulsion systems is much more developed in the laboratory than in practice. With a renewed emphasis on reducing engine life cycle costs, improving fuel efficiency, increasing durability and life, etc., driven by various government programs, there is a strong push to move these technologies out of the laboratory and onto the engine. This paper describes the existing state of engine control and on-board health management, and surveys some specific technologies under development that will enable an aircraft propulsion system to operate in an intelligent way-defined as self-diagnostic, self-prognostic, self-optimizing, and mission adaptable. These technologies offer the potential for creating extremely safe, highly reliable systems. The technologies will help to enable a level of performance that far exceeds that of today's propulsion systems in terms of reduction of harmful emissions, maximization of fuel efficiency, and minimization of noise, while improving system affordability and safety. Technologies that are discussed include various aspects of propulsion control, diagnostics, prognostics, and their integration. The paper focuses on the improvements that can be achieved through innovative software and algorithms. It concentrates on those areas that do not require significant advances in sensors and actuators to make them achievable, while acknowledging the additional benefit that can be realized when those technologies become available. The paper also discusses issues associated with the introduction of some of the technologies., The original document contains color images.

The C-17 T-1 Globemaster III is an Air Force flight research vehicle located at Edwards Air Force Base. NASA Dryden and the C-17 System Program Office have entered into a Memorandum of Agreement to permit NASA the use of the C-17 T-1 to conduct flight research on a mutually coordinated schedule. The C-17 Propulsion Control and Health Management (PCHM) Working Group was formed in order to foster discussion and coordinate planning amongst the various government agencies conducting PCHM research with a potential need for flight testing, and to communicate to the PCHM community the capabilities of the C-17 T-1 aircraft to support such flight testing. This paper documents the output of this Working Group, including a summary of the candidate PCHM technologies identified and their associated benefits relative to NASA goals and objectives., Additional Rept. no. E-14750. Prepared in cooperation with U.S. Army Research Laboratory, Cleveland, OH. Prepared in collaboration with Analytical Services and Materials, Inc., Edwards AFB, CA.

In this paper, an approach for in-flight fault detection and isolation (FDI) of aircraft engine sensors based on a bank of Kalman filters is developed. This approach utilizes multiple Kalman filters, each of which is designed based on a specific fault hypothesis. When the propulsion system experiences a fault, only one Kalman filter with the correct hypothesis is able to maintain the nominal estimation performance. Based on this knowledge, the isolation of faults is achieved. Since the propulsion system may experience component and actuator faults as well, a sensor FDI system must be robust in terms of avoiding misclassifications of any anomalies. The proposed approach utilizes a bank of (m+1) Kalman filters where m is the number of sensors being monitored. One Kalman filter is used for the detection of component and actuator faults while each of the other m filters detects a fault in a specific sensor. With this setup, the overall robustness of the sensor FDI system to anomalies is enhanced. Moreover, numerous component fault events can be accounted for by the FDI system. The sensor FDI system is applied to a commercial aircraft engine simulation, and its performance is evaluated at multiple power settings at a cruise operating point using various fault scenarios., Presented at the American Society of Mechanical Engineers Turbo Expo 2004, Vienna, Austria on June 14-17 2004. Rept no. GT2004-53640. Grant no. WBS-22-728-30-05.

Aircraft gas-turbine engine data are available from a variety of sources including on-board sensor measurements, maintenance histories, and component models. An ultimate goal of Propulsion Health Management (PHM) is to maximize the amount of meaningful information that can be extracted from disparate data sources to obtain comprehensive diagnostic and prognostic knowledge regarding the health of the engine. Data Fusion is the integration of data or information from multiple sources, to achieve improved accuracy and more specific inferences than can be obtained from the use of a single sensor alone. The basic tenet underlying the data/information fusion concept is to leverage all available information to enhance diagnostic visibility, increase diagnostic reliability and reduce the number of diagnostic false alarms. This paper describes a basic PHM Data Fusion architecture being developed in alignment with the NASA C17 Propulsion Health Management (PHM) Flight Test program. The challenge of how to maximize the meaningful information extracted from disparate data sources to obtain enhanced diagnostic and prognostic information regarding the health and condition of the engine is the primary goal of this endeavor. To address this challenge, NASA Glenn Research Center (GRC), NASA Dryden Flight Research Center (DFRC) and Pratt & Whitney (P&W) have formed a team with several small innovative technology companies to plan and conduct a research project in the area of data fusion as applied to PHM. Methodologies being developed and evaluated have been drawn from a wide range of areas including artificial intelligence, pattern recognition, statistical estimation, and fuzzy logic. This paper will provide a broad overview of this work, discuss some of the methodologies employed and give some illustrative examples., The original document contains color images. All DTIC reproductions will be in black and white. Presented at the (39th) Combustion/27th Airbreathing Propulsion/21st Propulsion Systems Hazards/3rd Modeling and Simulation Joint Subcommittee Meeting. sponsored by the Joint-Army-Navy-NASA-Air Force Interagency Propulsion Committee (JANNAF), Colorado Springs, Colorado on December 1-5, 2003.

NASA and the U.S. Department of Defense are conducting programs which support the future vision of "intelligent" aircraft engines for enhancing the affordability, performance, operability, safety, and reliability of aircraft propulsion systems. Intelligent engines will have advanced control and health management capabilities enabling these engines to be self-diagnostic, self-prognostic, and adaptive to optimize performance based upon the current condition of the engine or the current mission of the vehicle. Sensors are a critical technology necessary to enable the intelligent engine vision as they are relied upon to accurately collect the data required for engine control and health management. This paper reviews the anticipated sensor requirements to support the future vision of intelligent engines from a control and health management perspective. Propulsion control and health management technologies are discussed in the broad areas of active component controls, propulsion health management and distributed controls. In each of these three areas individual technologies will be described, input parameters necessary for control feedback or health management will be discussed, and sensor performance specifications for measuring these parameters will be summarized., Presented at the American Society of Mechanical Engineers Turbo Expo 2004, Vienna, Austria on June 14-17 2004. Rept no. GT2004-54324. Grant no. WBS-22-728-30-05.

In this paper, a bank of Kalman filters is applied to aircraft gas turbine engine sensor and actuator fault detection and isolation (FDI) in conjunction with the detection of component faults. This approach uses multiple Kalman filters, each of which is designed for detecting a specific sensor or actuator fault. In the event that a fault does occur, all filters except the one using the correct hypothesis will produce large estimation errors, thereby isolating the specific fault. In the meantime, a set of parameters that indicate engine component performance is estimated for the detection of abrupt degradation. The proposed FDI approach is applied to a nonlinear engine simulation at nominal and aged conditions, and the evaluation results for various engine faults at cruise operating conditions are given. The ability of the proposed approach to reliably detect and isolate sensor and actuator faults is demonstrated. (7 tables, 4 figures, 17 refs.), Presented at the American Society of Mechanical Engineers and the International Gas Turbine Institute, Atlanta, Georgia, 16-19 Jun 2003. Prepared in collaboration with QSS Group, Inc., Cleveland, OH. WBS-22-728-30-20. GT2003-38550.

Kalman filters are often used to estimate the state variables of a dynamic system. However, in the application of Kalman filters some known signal information is often either ignored or dealt with heuristically. For instance, state variable constraints (which may be based on physical considerations) are often neglected because they do not fit easily into the structure of the Kalman filter. This paper develops an analytic method of incorporating state variable inequality constraints in the Kalman filter. The resultant filter is a combination of a standard Kalman filter and a quadratic programming problem. The incorporation of state variable constraints increases the computational effort of the filter but significantly improves its estimation accuracy. The improvement is proven theoretically and shown via simulation results obtained from application to a turbofan engine model. This model contains 16 state variables, 12 measurements, and 8 component health parameters. It is shown that the new algorithms provide improved performance in this example over unconstrained Kalman filtering., Prepared for the Turbo Expo (2003) cosponsored by the American Society of Mechanical Engineers and the International Gas Turbine Institute, Atlanta, GA, 16-29 Jun 2003. GT2003-38584.

Kalman filters are often used to estimate the state variables of a dynamic system. However, in the application of Kalman filters some known signal information is often either ignored or dealt with heuristically. For instance, state variable constraints (which may be based on physical considerations) are often neglected because they do not fit easily into the structure of the Kalman filter. This paper develops two analytic methods of incorporating state variable inequality constraints in the Kalman filter. The first method is a general technique of using hard constraints to enforce inequalities on the state variable estimates. The resultant filter is a combination of a standard Kalman filter and a quadratic programming problem. The second method uses soft constraints to estimate state variables that are known to vary slowly with time. (Soft constraints are constraints that are required to be approximately satisfied rather than exactly satisfied.) The incorporation of state variable constraints increases the computational effort of the filter but significantly improves its estimation accuracy. The improvement is proven theoretically and shown via simulation results. The use of the algorithm is demonstrated on a linearized simulation of a turbofan engine to estimate health parameters. The turbofan engine model contains 16 state variables, 12 measurements, and 8 component health parameters. It is shown that the new algorithms provide improved performance in this example over unconstrained Kalman filtering., Sponsored in part by a NASA/ASEE Summer Faculty Fellowship.

A key to producing reliable engine diagnostics and prognostics resides in the fusion of different processing techniques. Fusion of techniques has been shown to improve diagnostic performance while simultaneously reducing false alarms. Presented here is an approach that fuses a physical model called STORM (Self Tuning Onboard, Real-time engine Model) developed by Pratt & Whitney, with an empirical neural net model to provide a unique hybrid model called enhanced STORM (eSTORM) for engine diagnostics. STORM is a piecewise linear approximation of the engine cycle deck. Though STORM provides significant improvement over existing real-time engine model methods, there are several effects that impact engine performance that STORM does not capture. Integrating an empirical model with STORM accommodates the modeling errors. This paper describes the development of eSTORM for a Pratt & Whitney high bypass turbofan engine. Results of using STORM and eSTORM on simulated engine data are presented and compared. eSTORM is shown to work extremely well in reducing STORM modeling errors and biases for the conditions considered., Presented at the IEEE Aerospace Conference, held in Big Sky, MT on March 2003. Published in the Proceedings of the IEEE Aerospace Conference, 2003. Paper number 1023. The original document contains color images.

In this paper, a model-based diagnostic method, which utilizes Neural Networks and Genetic Algorithms, is investigated. Neural networks are applied to estimate the engine internal health, and Genetic Algorithms are applied for sensor bias detection and estimation. This hybrid approach takes advantage of the nonlinear estimation capability provided by neural networks while improving the robustness to measurement uncertainty through the application of Genetic Algorithms. The hybrid diagnostic technique also has the ability to rank multiple potential solutions for a given set of anomalous sensor measurements in order to reduce false alarms and missed detections. The performance of the hybrid diagnostic technique is evaluated through some case studies derived from a turbofan engine simulation. The results show this approach is promising for reliable diagnostics of aircraft engines.

The NASA Aviation Safety Program (AvSP) has been initiated with aggressive goals to reduce the civil aviation accident rate. To meet these goals, several technology investment areas have been identified including a sub-element in propulsion health monitoring (PHM). Specific AvSP PHM objectives are to develop and validate propulsion system health monitoring technologies designed to prevent engine malfunctions from occurring in flight, and to mitigate detrimental effects in the event an in-flight malfunction does occur. A review of available propulsion system safety information was conducted to help prioritize PHM areas to focus on under the AvSP. It is noted that when a propulsion malfunction is involved in an aviation accident or incident, it is often a contributing factor rather than the sole cause for the event. Challenging aspects of the development and implementation of PHM technology such as cost, weight, robustness, and reliability are discussed. Specific technology plans are overviewed including vibration diagnostics, model-based controls and diagnostics, advanced instrumentation, and general aviation propulsion system health monitoring technology. Propulsion system health monitoring, in addition to engine design, inspection, maintenance, and pilot training and awareness, is intrinsic to enhancing aviation propulsion system safety.

Aircraft Engine Health Management Data Mining Tools is a project led by NASA Glenn Research Center in support of the NASA Aviation Safety Program's Aviation System Monitoring and Modeling Thrust. The objective of the Glenn-led effort is to develop enhanced aircraft engine health management prognostic and diagnostic methods through the application of data mining technologies to operational data and maintenance records. This will lead to the improved safety of air transportation, optimized scheduling of engine maintenance, and optimization of engine usage. This paper presents a road map for achieving these goals.