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www.impact-tek.com 2008, Impact Technologies, LLC All Rights Reserved 1 Impact Technologies, LLC Some Recent Developments Carl Byington, P.E. Principal and Director of Systems Engineering Impact Technologies, LLC carl.byington@impact-tek.com 585-627-1926

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2008, Impact Technologies, LLC All Rights Reserved www.impact-tek.com 2 What We Do Develop and field sensors, systems, and software that monitor, detect, isolate, predict, adapt control, and plan Provide services to our customer to reduce risk, increase safety, improve readiness, and minimize ownership costs

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2008, Impact Technologies, LLC All Rights Reserved www.impact-tek.com 3 Some new stuff we have been working on.

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2008, Impact Technologies, LLC All Rights Reserved www.impact-tek.com 4 Integrated Vehicle Health Monitoring Solutions

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2008, Impact Technologies, LLC All Rights Reserved www.impact-tek.com 5 Drive train Main gearbox Tailrotor gearbox Engine Vibration Engine Performance Electromechanical Actuators Rotor Balancing Demonstration of Generation 1 IVHM system

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2008, Impact Technologies, LLC All Rights Reserved www.impact-tek.com 6 Web-Enabled Fleet Access Concept

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2008, Impact Technologies, LLC All Rights Reserved www.impact-tek.com 7 Potential applications General Atomics MQ-1C Sky Warrior MQ-1 Predator MQ-9 Reaper Unmanned doesnt mean just aerial vehicles! Northrop Grumman RQ-8 Fire Scout RQ-4 Global Hawk Lockheed Martin MULE Navy SPAWAR Spartan Scout

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2008, Impact Technologies, LLC All Rights Reserved www.impact-tek.com 8 Vibration-Based PHM Solutions Extensive Successful Field Application Experience Aircraft Engine OEM Test Cell Engine OEM Onboard PHM Bearing and Power Transmission Component OEM Navy and Army Helicopter Platforms Various DoD and Industrial Applications ImpactEnergy Bearing Module GearMod Gear Module GearMod Shaft Shaft Module Firstcheck Sensor Module

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2008, Impact Technologies, LLC All Rights Reserved www.impact-tek.com 9 In-line Lubricant Quality Interrogation Using Smart Oil Sensor Multisensor fluid quality monitor Broadband Impedance Spectroscopy, RH, Temperature measurements Uses patented broadband measurement technique Measure more fluid parameters => trend more fluid contaminants Much faster than traditional EIS measurements US Patent Number 7,239,155 Onboard processing Impedance and feature calculations Diagnostic and prognostic algorithms CAN, RS232, and other communications interfaces Adapting a version for aircraft applications

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2008, Impact Technologies, LLC All Rights Reserved www.impact-tek.com 10 Structural Corrosion PHM Leverage sensing and embedded systems expertise to create an ultra-low power sensing device for use in detecting corrosive environments Features Real-time, In-situ Corrosivity Monitor Multi-Sensor Design Low Power Miniature, Light Weight Embedded Processing Wired / Wireless Communication

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2008, Impact Technologies, LLC All Rights Reserved www.impact-tek.com 11 Advancing Non-destructive Inspection for Composites Disbond Repair F-15 Stabilator Section

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2008, Impact Technologies, LLC All Rights Reserved www.impact-tek.com 12 mLIFE Rocket Motor Life Prediction Software

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2008, Impact Technologies, LLC All Rights Reserved www.impact-tek.com 13 Wireless Monitoring on Landing Systems Integration of multiple sensing and wireless transmission to remote processing display

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2008, Impact Technologies, LLC All Rights Reserved www.impact-tek.com 14 Helicopter Component Prognostics Improvement Program Raw data Data- driven CIs Fusion Physics-of- failure mechanisms Model- based CIs Damage progression mechanisms Diagnostics: current health state Prognostics: future health state Usage / operating conditions Experience (FMECA, RCM)

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2008, Impact Technologies, LLC All Rights Reserved www.impact-tek.com 15 Improving Strain Gauge Calibration Factor Assessment Replace time consuming static loading or special flight tests to calibrate strain sensors. Static Load Test

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2008, Impact Technologies, LLC All Rights Reserved www.impact-tek.com 16 Force and Strain Measurements for Input Excitation and Structural Response Strain Gages Bonded-foil resistance strain gages: small wire or foil grid on a thin polymer substrate Piezoresistive (semiconductor) bonded to structure or deposited as a thin-film Load Cell attached to a shaker or integrated to an impact hammer Data Acquisition using NI equipment & LabVIEW Strain Gage Shaker Load Cell

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2008, Impact Technologies, LLC All Rights Reserved www.impact-tek.com 17 Concept Verification Tests Periodic Excitation Test Tabulate excitation frequency, input force, strain output, CF, and deviation of CF (test mode 1 configuration and periodic excitation on location 1) Average = 1.062 compare to 1.07 for Static

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2008, Impact Technologies, LLC All Rights Reserved www.impact-tek.com 18 NASA NRA EMA Test Stand and Software Package

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2008, Impact Technologies, LLC All Rights Reserved www.impact-tek.com 19 Virtual Test Environment (VTE) Consists of components that enable actuator testing Controller Drive Loading Mechanism Sensors User Interface Dynamically links test and load EMAs Standardized controller, drive, & sensors blocks

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2008, Impact Technologies, LLC All Rights Reserved www.impact-tek.com 20 Initial PHM Results Preliminary fault assessment routines have been developed Implements reduced order (static) actuator model and automated optimization routine to obtain model parameters that minimize error Full, dynamic model used to simulate actual system response Virtual Test Environment used to simulate 3 EMA faults IDd from PHM Design analysis Motor bearing wear/lubrication degradation (friction increases) Motor winding short Position sensor fault

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2008, Impact Technologies, LLC All Rights Reserved www.impact-tek.com 21 3 days of intensive PHM experiences at annual workshop in Miami, FL Attended by government and industry; developers and end users Training and networking opportunity