ADT 101: Introduction to the Airframe Digital Twin Concept 13 Feb

ADT 101: Introduction to the Airframe Digital Twin Concept 13 Feb 2013 Integrity Service Excellence Eric Tuegel AFRL/RQVS Air Force Research Laboratory DISTRIBUTION A. Approved for Public Release; Distribution Unlimited. 1

Outline What is an ADT? Why an ADT? Vision of how an ADT might be used R&D Taxonomy for the ADT – Definitions of Taxonomy elements DISTRIBUTION A. Approved for Public Release; Distribution Unlimited. 2

What is an ADT? Plan nce en a t n i Ma Usa g Applied Loads & Environments (Probabilistic) e State Up dat e ate d p U Range of Structural Response & Reliability (Probabilistic) Geometry & Material Data (Probabilistic) Airframe Digital Twin Physics-based Multiscale, Multi-Discipline Models DISTRIBUTION A. Approved for Public Release; Distribution Unlimited. 3

ADT Definition Integrated system of data, models, and analysis tools to represent an airframe over its entire life cycle To provide actionable information for making decisions Now (diagnosis) and for the future (prognosis) On a fleet-wide and individual tail number basis Considering all sources of uncertainty DISTRIBUTION A. Approved for Public Release; Distribution Unlimited. 4

Functional ADT Flowchart Update history as new damage state and usage information is gathered Reliability Sufficient 1.E 00 Prognostics History Health History Failure History Mission History Maintenance History Model Information Spare Assets Update configuration Structural Analysis 1.E -01 1.E -02 Single Flight Probability of Failure Probabilistic Decision Making 1.E -03 1.E -04 1.E -05 1.E -06 1.E -07 1.E -08 1.E -09 1.E -10 1.E-11 1.E -12 1.E -13 1.E -14 0 2000 4000 6000 Flight Hours 8000 10000 12000 State of Health Remaining Useful Life (RUL) Rate of Change Time to Action Problem Identification Components Affected Recommendations Confidence Mission Readiness Remarks/Comments Reliability Insufficient DISTRIBUTION A. Approved for Public Release; Distribution Unlimited. 5

Why an ADT? Many different information streams over the life of an aircraft Provide a singe location where all information is collected – Able to find and use the information throughout the lifecycle Separate information by individual aircraft Information includes data, analysis models, etc. – Verification and Validation of information is important DISTRIBUTION A. Approved for Public Release; Distribution Unlimited. 6

Uses of the ADT (1 of 3) Design – Nominal ADT created as framework for individuals – Use to assess reliability of overall design – Manage design changes Manufacturing & Assembly – – – – Collect data on individual aircraft as-built Create unique ADT for each tail number Use to disposition any discrepancies Configuration control of individual aircraft “Digital “Digital Thread” Thread” Integrating Integrating across across these these Phases. Phases. DISTRIBUTION A. Approved for Public Release; Distribution Unlimited. 7

Uses of the ADT (2 of 3) Testing & Evaluation – Validate or calibrate models in ADT – Simulate conditions impossible to test – Use to resolve anomalous test results Use Use Deterministic, Deterministic, “Design-to” “Design-to” Model Model Now Now DISTRIBUTION A. Approved for Public Release; Distribution Unlimited. 8

Uses of the ADT (3 of 3) Operations – Force structure planning – Asset selection for mission Maintenance, Repair & Overhaul – – – – – – Schedule and Plan Maintenance Capture field maintenance data Spares Planning Design Repairs Configuration Control of Individual Aircraft Problem Resolution Several Several SPO’s SPO’s Have Have Maintenance Maintenance Databases Databases DISTRIBUTION A. Approved for Public Release; Distribution Unlimited. 9

ADT R&D Taxonomy Design Design T&E T&E Manufacturing Manufacturing Assembly && Assembly Operations Operations Sustainment Sustainment MRO && MRO Usage State Awareness Structural/Life Analysis Data Management Computing / Computational Techniques Probabilistic Support for Decisions Integrated Architecture DISTRIBUTION A. Approved for Public Release; Distribution Unlimited. 10

Usage External macro-conditions applied to and experienced by the aircraft as a whole – Aerodynamic loads – Environmental conditions (humidity, salt spray, etc.) – Heat flux (frictional heating, exhaust impingement) Applied to ADT as boundary conditions or forcing functions DISTRIBUTION A. Approved for Public Release; Distribution Unlimited. 11

State Awareness Knowledge of the condition of the airframe from direct observation – Micro and macro conditions Initial state from material & process specs, fabrication info w/ process models, design constraints, and NDI – Initial conditions for the ADT Operational state from NDI and documented evidence of repair or replacement – Continuous validation of the ADT DISTRIBUTION A. Approved for Public Release; Distribution Unlimited. 12

Structural & Life Analysis Integrated collection of multi-scale, multidiscipline, multi-fidelity models of the airframe – Quantify uncertainty probabilistically Outputs: structural displacements, strains, and stresses; evolution of the structural, material, and damage states; and estimates future airframe condition given the proposed usage DISTRIBUTION A. Approved for Public Release; Distribution Unlimited. 13

Data Management Architecture and procedures for: – – – – Assuring and maintaining integrity of information Storing information Accessing desired information later Manipulating desired information (visualization, etc.) Types of information: – – – – Usage (flight records) State of airframe (inspection records) Analysis models and results Maintenance records DISTRIBUTION A. Approved for Public Release; Distribution Unlimited. 14

Computing Hardware and software architectures required to efficiently execute the Structural & Life Analysis models, and access information DISTRIBUTION A. Approved for Public Release; Distribution Unlimited. 15

Probabilistic Decision Support Approaches for quantifying and managing uncertainty in the ADT Verification & Validation of ADT – Or possibly calibrating Tools for making decisions from uncertain information (quantified uncertainty) Affects: – Model development and execution – Data collection, archiving, and retrieval DISTRIBUTION A. Approved for Public Release; Distribution Unlimited. 16

Integrated Architecture Definition and management of the information flow between all components of the ADT, as well as between the ADT and the external world Service-oriented, modular, open architecture – Securely delivers the right information to the right person at the right time DISTRIBUTION A. Approved for Public Release; Distribution Unlimited. 17

Design Definition of the structural configuration – – – – – Requirements: original and derived Design Allowables Geometry and Tolerances Materials Specifications Process Specifications Developmental testing to support Design Allowables DISTRIBUTION A. Approved for Public Release; Distribution Unlimited. 18

Manufacturing & Assembly What is actually built and how it is built – – – – – Actual Material Properties (ICME if possible) Actual dimensions of parts and assemblies Fit up and shimming Process controls and records Discrepancies and dispositions DISTRIBUTION A. Approved for Public Release; Distribution Unlimited. 19

Test & Evaluation Certification and Validation of the Design – Ground Tests – Flight Tests – Operational Readiness Tests Test Conditions and Results DISTRIBUTION A. Approved for Public Release; Distribution Unlimited. 20

Operations Aircraft is available and mission capable – Environment while on the ground – Ground handling and Payload loading – Flight loads and environment DISTRIBUTION A. Approved for Public Release; Distribution Unlimited. 21

Maintenance, Repair & Overhaul Inspections and maintenance at any location – Inspections and findings Including disassembly for access – Repairs – Modifications – Program Depot Maintenance DISTRIBUTION A. Approved for Public Release; Distribution Unlimited. 22

Conclusion Still a work in progress The ADT will have many uses – good thing DISTRIBUTION A. Approved for Public Release; Distribution Unlimited. 23