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Integrated vehicle health management has been developed for several years in different industries, to be able to provide the required inputs to determine the optimal maintenance operations depending on the actual health status of the system. The purpose of this paper is to demonstrate the potential of a physics-based model (PbM) for prognostics with a real case study, based on the detection of incipient faults and estimate the remaining useful life of a planetary transmission of an aircraft system.

Most of the research in the area of health assessment algorithms has been focused on data-driven approaches that are not based on the knowledge of the physics of the system, while PbM approaches rely on the understanding of the system and the degradation mechanisms. A physics-based modelling approach to represent metal-metal contact and fatigue in the gears of the planetary transmission of an aircraft system is applied.

Both the failure mode caused by metal-metal contact as caused by fatigue in the gears is described. Furthermore, the real-time application that retrieves the results from the simulations to assess the health of the system is described. Finally the decision making that can be executed during flight in the aircraft is incorporated.

The paper proposes an innovative prognostics health management system that assesses two important failure modes of the planetary transmission that regulates the speed of the generators of an aircraft. The results from the models have been integrated in an application that emulates a real system in the aircraft and computes the remaining useful life in real time.

This paper aims to present the procedures necessary to determine the insert allowable for a composite sandwich, considering that the inserts were the most commonly used means to install equipment on the composite structure of Clean Sky 2 (CS2)-RACER compound helicopter.

The installation of the equipment inside of the airframe shall comply with the certification regulations, especially in relation to the inertial factors. Establishing of the needed number of inserts to fix the equipment is directly linked to the allowable coming from coupon tests. The materials and test procedures to which they were subjected are part of the process qualification used in the development of the CS2-RACER Main Fuselage. The samples were tested in two different static mechanical loadings, consisting of pull-out insert and shear-out insert tests. The mechanical behaviour and failure mechanism of the materials were evaluated using optical and scanning electron microscopy.

The insert installation on the sandwich structure influences the behaviour and mechanical properties during pull-out and shear-out testing.

The limited data available in standardized documents related to insert testing makes it difficult to compare results with certified baseline values.

To reduce the effort of selecting the optimized insert system, specific parameters are included in analytical pre-sizing, i.e. type of loads, geometry, materials, failure modes, special conditions such as manufacturing and testing.

The results of the study presenting the design, manufacturing and mechanical testing of pull-out and shear-out inserts used in composite materials sandwich-type coupons provide valuable information regarding the insert allowable determination.