TECHNOLOGY AREA(S): Battlespace, Electronics, Sensors

ACQUISITION PROGRAM: PMS 325G, Support Ships, Boats and Craft

OBJECTIVE: Develop and implement a system that includes real-time recording, monitoring and data analytics, diagnostic, and prognostic capabilities for manned craft extensible to unmanned vessels.

DESCRIPTION: This topic seeks to develop an innovative solution for a craft data acquisition, processing, and display system capable of simultaneously receiving inputs in various data formats from relevant onboard sources as well as sensors from other applicable development projects for processing and/or storage on removable or uploadable media for future analysis.� The Health Monitoring System (HMS) at a minimum must have recording, diagnostic, and prognostic system capability in order to identify maintenance/repair issues as well as provide post-mission forensic analysis and playback of maintenance and operational data in order to understand all aspects of the craft and human environment during the course of a mission.� The HMS should provide a mechanism to assist in identifying root cause of minor, significant and catastrophic craft, systems, and component failures.� Characterization of group-wide maintenance and repair issues will provide potentially significant savings by forecasting system degradation especially in critical operating environments that could have devastating results in loss of assets or personnel.

The HMS should have diagnostic and prognostic capabilities in order to identify system issues and predict future failure modes.� The HMS should have the ability to assist in identifying means to improve operations for reduced cost, identify areas for reduced maintenance intervals, target maintenance actions, predict imminent failures, and offer means for root cause analysis of failures while providing insight into total craft mission performance.� Data analytics is a key component of the system and a primary area for innovation to adapt or field new algorithms and techniques to meet the objectives listed.� The HMS should also provide a real-time display for guiding a craft operator towards reduced fuel consumption, optimized energy consumption, and cue attention to imminent system faults.� Post-mission, the HMS should also assist a craft operator in rapidly understanding the environmental severity of a mission and cueing to any particular anomalies.

Capabilities should include secure electronic transfer (Wi-Fi or Radio Frequency (RF) data link and interface cable) and physical transfer (removable storage media) of craft data to a dedicated shore station.� The shore station post processing and �digital dashboard� is a critical feature that will provide the human interface for the desired situational awareness, required actions and trends to monitor.� The shore station should allow an operator to view any part of a mission and key filtered data.� The shore station should also allow an operator to display, recreate, playback, and/or print mission critical craft system parameters (engine, gearbox, fluid systems, power, etc.) and operating environment to include, at a minimum, craft motions and high shock events with a virtual craft mimicking motions encountered.� Mission playback should include location on digital nautical charts and overlay Automatic Radar Plotting Aids (ARPA) and Automatic Identification System (AIS) contacts as well as provide a histogram laid format over a human and craft performance limit trend lines.� The HMS should record all data with Global Positioning System (GPS) and time stamp information, as well as provide video Electro-Optical/ Infrared (EO/IR) data and communications recording and playback.� GPS data capture should have the capability to be disabled.� System shall have ability to turn off, physically disable GPS tracking without negatively effecting system performance, and shift graphical user interface to provide new user environment without blank screens or data fields.� Shore station shall provide provisions to organize multiple craft data sets and transmit data over the internet to server for fleet-wide analysis and trending from a central location.� System architecture should be flexible enough to add real time capability at a later date and underway data transfer link over satellite radio or Line of Sight radio to promote the extensibility to unmanned craft Command and Control (C2) system integration.

The final HMS should be packaged in a relatively small footprint, meet marine standards, and be hardened in order to survive a catastrophic craft event.� The HMS should also be capable of being easily mounted inside craft with military specification connections.� The weight of the controller should not exceed 20 pounds.� The power connection should accept between 10 and 28 volts DC. The HMS�s internal components should be suitable for the environment specifications and not include unique custom components unavailable without long lead times. Mechanical drives should not be used for the final design.

The HMS should not require custom firmware or operating system.� The software should have diagnostic features such as a system heartbeat that is remotely available or broadcasted.� All software should be capable of successfully running on a standard Navy Marine Corp Internet (NMCI) laptop.

The shore-side part of the HMS should be a commercially available laptop that does not require special components or software and be similar to a standard NMCI laptop in performance/capabilities.

The typical environmental requirements for equipment on the craft are as follows:

Moisture: 99% humidity, condensing.
Temperature, Ambient:� -40 to 154 degrees Fahrenheit.
Shock: 10g vertical/100msec half sine pulse, 5g lateral/100msec half sine pulse.
Vibration: Capable of surviving and remaining fully operable in accordance with MIL-STD-810G Method 514.6 in the presence of random vibration defined by the vertical power spectral density (PSD) curve of Figure 514.6C3, one hour in each required axes.
Repeated Operational Wave Slam: Equipment shall be able to perform its normal functions during and following exposure to 1.5g, 100 msec half-sine pulses, 800 pulses at 1.0 second intervals.
Corrosion Control: All fasteners shall be corrosion resistant steel, conforming to UNS S31600. Exterior surfaces and connectors shall be able to withstand testing in accordance with MIL-STD-810G Method 509.5 for salt fog environments.
Electromagnetic Interference: International Electrotechnical Commission (IEC)

PHASE I: Develop a concept for a Combatant Craft Health Monitoring System. No hardware is expected to be designed or prototyped.� The contractor at this point should be very specific in the design approach, data acquisition system design, shore station design, and software design.� Define the proposed algorithms for a HMS.� Craft shock processing algorithms for development of histogram will be provided by the Government.� The Phase I Option, if awarded, will include the initial design specifications and capabilities description to build a prototype HMS in Phase II.� Develop a Phase II plan.

PHASE II: Based on the results of Phase I and the Phase II Statement of Work (SOW), develop and deliver a full-scale prototype to the Navy for evaluation.� The prototyped onboard and shore-side hardware with beta phase of software should be operational. The prototyped hardware should be a seaworthy, hardened system.

PHASE III DUAL USE APPLICATIONS: Support the Navy in transitioning the technology for Navy use.� The fully hardened HMS for sea trials should be demonstrated successfully on a manned or unmanned vessel.� The HMS should pass an underway test plan to be developed for the defined test platform.

Marine, air, and land vehicle electronics industries will benefit from this HMS.� This type of system can be applied to any vehicle to provide diagnostic and prognostic system capability in order to identify maintenance/repair issues, provide performance analysis and playback, and assist in identifying root cause of catastrophic or significant and minor vehicle, systems, and component failures.

REFERENCES:

1. Dekate, Deepali A. �Prognostics and Engine Health Management of Vehicle using Automotive Sensor Systems.� International Journal of Science and Research (IJSR), Volume 2 Issue 2, February 2013, India Online ISSN: 2319-7064, 1PVPIT, Department of Electronics & Telecommunication, University of Pune, Maharashtra, India. https://www.ijsr.net/archive/v2i2/IJSRON2013443.pdf

2. Kilby, T. Scott, Rabeno, Eric, and Harvey, James. �Enabling Condition Based Maintenance with Health and Usage Monitoring Systems.� AIAC14 Fourteenth Australian International Aerospace Congress Seventh DSTO International Conference on Health & Usage Monitoring. (HUMS 2011) Field Studies Branch, Logistics Analysis Division, USAMSAA. http://www.humsconference.com.au/Papers2011/Kilby_S_Enabling_Condition_Based_Maintenance.pdf

3. Kilchenstein, Greg. �SAE Aerospace Standards Summit Condition Based Maintenance.� 08 July 2015; https://www.sae.org/standardsdev/summit/presentations/kilchenstein-condition_based.pdf

KEYWORDS: Data acquisition; Health Monitoring System; Performance Monitoring; Onboard Diagnostics; Prognostics; Failure Mode and Effects Analysis