SH-60 helicopter integrated diagnostic system (HIDS) program-diagnostic and prognostic development experience

The evolution of automated diagnostic systems for helicopter mechanical systems has been aided by a Navy program of systematic testing of drive train components having known anomalies (seeded faults) while simultaneously executing a suite of diagnostic techniques to identify and classify the mechanical anomalies. This program, called the Helicopter Integrated Diagnostic System (HIDS) has been carried out using an iron bird test stand (SH-60) at NAWC - Trenton, and SH-60B/F flight vehicles at NAWC - Patuxent River. The SH-60 HIDS program has been the Navy's cornerstone effort to develop, demonstrate, and justify integrated mechanical diagnostic system capabilities for its helicopter fleets. The objectives of the program were to: 1. Acquire raw data for multiple cases of "good" and seeded fault mechanical components on a fully instrumented drive train to support the evaluation of diagnostic algorithms and fault isolation matrices. 2. Analyze vibration and other diagnostic indicators 3. Demonstrate the ability to integrate and automate the data acquisition, diagnostic, fault evaluation and communication processes in a flight worthy system. 4. Integrate and evaluate comprehensive engine monitoring, gearbox and drive train vibration diagnostics, advanced oil debris monitoring, inflight rotor track and balance, parts life usage tracking, automated flight regime recognition, power assurance checks and trending, and automated maintenance forecasting in a well-coordinated on-board and ground-based system. 5. Provide an extensive library of high quality vibration data on baseline and seeded fault components. 6. Provide a "showcase", state-of-the-art, fully functional Integrated Mechanical Diagnostic system to act as a catalyst demonstration. This paper describes the overall program, the goals and objectives, the facilities used, the system evaluated, accomplishments, results and conclusions obtained to date, The results of extensive gearbox and power-train "seeded fault" testing are presented. Lessons learned that can be applied to future Helicopter Usage Monitoring Systems (HUMS) and/or Integrated Mechanical Diagnostic (IMD) systems are also discussed.