Use and benefit of seeded fault testing in development of advanced diagnostic and prognostic algorithms

Seeded fault testing is defined as the process of installing used parts with a quantified service created defect into an otherwise healthy piece of equipment for the purpose of developing diagnostic and prognostic techniques to identify impending failure in that piece of equipment. Having conducted seeded fault testing of an installed and fully functional but non-flying Bell 206 helicopter gearbox, it has been found that application of seeded fault techniques can produce significant benefits relative to the validation and subsequent use of prognostic and diagnostic algorithms. Having developed a level of expertise on the Bell 206, additional plans are being developed to conduct seeded fault testing of a T56 propeller reduction gearbox prior to moving to the complete installed engine assembly. The work completed so far has shown that in complex equipment, some prognostic and diagnostic techniques are valid and in other cases shown some techniques to be invalid even though they may have worked in less complex equipment. Development of a database of seeded fault data for general industry provides an essential tool for evaluation and refinement of future algorithms. Early application of seeded fault test data in a program using a condition based maintenance approach on complex mechanical equipment has in many industries produced significant benefits for the equipment operators in terms of higher equipment availability, lower operating costs and increased safety.