Real time Optoelectronic Sensors for Electro-Actuator Hydraulic Fluid Contamination Monitoring

Project Information

FluidER

Grant agreement ID: 831998

DOI

10.3030/831998

Project closed

EC signature date 13 March 2019

Start date 1 April 2019

End date 30 September 2021

Funded under

• SOCIETAL CHALLENGES - Smart, Green And Integrated Transport

Total cost

€ 560 982,50

EU contribution

€ 498 451,25

Coordinated by

FUNDACION TEKNIKER
Spain

Periodic Reporting for period 2 - FluidER (Real time Optoelectronic Sensors for Electro-Actuator Hydraulic Fluid Contamination Monitoring)

Reporting period: 2020-10-01 to 2021-09-30

Summary of the context and overall objectives of the project

The overall objective of FluidER project is to deliver an integrated solution for in-line sensing and diagnosis of aviation hydraulic fluids and the associated hydraulic actuators. This principal objective is translated into 6 smaller objectives:
Objective 1: In-Line Fluid Parameter and Contaminant Sensing
The first objective is focused on setting up the different sensor technologies for their use in the EHA Hydraulic Fluid applications. Additionally, objective 1 also aims to deliver the right sensor installation approach, considering the specific requirements of the specimen EHA provided by the Topic Manager.
Objective 2:Design of Experiment and associated Test Environment Setting and Running
The equipment and resources available at consortium members’ facilities was used to set the expected Test Environments: (i)hydraulic test beds, (ii)EHA test beds and (iii)parallel Analytical Laboratory tests complementing and supporting the previous tests.
Objective 3:Measurement Correlation and Health Condition Algorithms:
To develop, implement and integrate Health Monitoring algorithms for the early detection and prediction of unacceptable levels of contamination of the fluid.
Objective 4.:FluidER System Reliability for Aeronautical Environment
To identify and upgrade FluidER system’s critical components towards to compliance with aircraft environments in the frame of a TRL5-6 technology.
Objective 5. System Validation
To validate the contamination monitoring system and the health condition algorithms at different test environments: (i) controlled laboratory environment with artificially contaminated fluid samples, (ii) HA test bed simulating relevant working conditions).
Objective 6. Business Case Assessment
To provide an overview of the Total Cost of Operation of proposed monitoring system.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The objective of WP1 is to define the detailed Design of Experiments (DoE). The foremost objective of this DoE is to assure that representative information is gathered to enable a solid correlation definition. Additionally, This WP1 covers the activities for preparing the different sensor systems (Fluid Parameter sensors and Fluid Contamination Sensors) for the HA test environment and will start the activities for artificially degrading the Hydraulic Fluids to have them ready by the due date of experiment start in the next WPs.
WP2 will be focused on delivering the Alfa Generation Health Algorithms for Fluid status monitoring. This Alfa version algorithm was based in expert knowledge. These correlations will be based on the quantitative and qualitative information acquired from the Laboratory Analysis of HF Samples (artificially degraded ones and the real samples provided by the Topic Manager) and the information outputted by the HF sensors installed on a Hydraulic Test Bed when the same HF samples are fed into it.
WP3 goes one step forward and moves the test environment from laboratory to the HA test bed. This WP includes the setup of the HA test bed, including the installation of the Topic Manager’s HA and the deployment of the different sensors (fluid property sensors, fluid contamination sensors and HA condition sensors). Artificially degraded fluid samples were analysed in the test Fluider test bench. The successful accomplishment of the defined test will accredit the TRL4 of the system, and the data set and insights gathered will be the base for the development of the second generation (Beta) of the Health Condition Algorithms, which will be fed into the experimental activities of the next WP.
WP4 is devoted to assessing the performance of both, sensors, and Beta-Algorithms at the HA Test-Bed towards the TRL5-grade evaluation. Within this WP, a final fine-tuning of the different algorithms and components is expected, with the aim of enabling the FluidER solution for the TRL6 assessment under the testing conditions defined by SAFRAN LANDING SYSTEMS. The data obtained from the health state of the actuator will be inked with the data obtained from the FLUIDER sensing system.
WP5 is directed towards managing the overall project tasks and coordinating activities between partners to ensure successful and timely delivery of project deliverables. The activities related to interfacing with Topic Leader and dissemination of project findings and results to scientific and industrial communities will be managed. The total cost of ownership of the proposed monitoring solution of FluidER project will also be assessed and updated over the lifetime of the project.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

FluidER project developed and delivered an integrated and autonomous system for sensing and diagnosis of aviation hydraulic fluids. The system enables to have an early warning of degradation signs, in terms of particulate count, viscosity, AN, and water contamination, before the hydraulic fluids exceeds the service limits. The information obtained from the different sensors is used to generate a Diagnosis of the status of both, the fluid itself and the HA equipment, through new health monitoring algorithms.
The integration of health monitoring technologies add intelligence into the system ensuring robust data transmission, meet the reliability requirements and endure environmental requirements from aircraft equipment.
The maintenance cost will be reduced, and maintenance operations will be improved. It is common in the industry to send fluid samples to analyze in laboratory, with the Fluider system this will be reduced.Besides there is an additional advantage, the time to obtain the health state of the fluid is reduced, as the results will be obtained in a matter of minutes, instead of days. Having the Fluider system may increase the number of analysis, as some analysis may not be done because cost or time drawbaks. This has the potential to improve maintenance cost and efficiency of operations.
FluidER system improves Hydraulic Actuators (HA) systems efficiency in terms of:
- Reduced HA maintenance cost and improve maintenance operations efficiency
- Preventing detrimental effects on the equipment lifetime: Preventive and predictive maintenance
- Increased reliability of the hydraulic fluid health monitoring data
- Increased life length of hydraulic actuators
FluidER is completely aligned with the Systems ITD targets (reduction of CO2, NOx, noise) by the improvement of competitiveness contribution to the introduction of full electrical actuator and the reduction of maintenance costs and increase the system data reliability.
FluidER contributes in the WP4.1 “Advanced Landing Systems” and its target of achieving “full electrical main landing gear” by the improvement of the HA reliability and safety and life extension.

Researcher working on the phosphate ester fluid test bench.

Test bench simulating working conditions for actuator