Reliability Based Design Recommendations for an Electromechanical Actuator Test Stand



Michael T. Koopmans Rudolph C. Hooven Irem Y. Tumer


The quality and robustness of data sets of faulted electromechanical actuators (EMAs) are necessary to strengthen aircraft prognostic data analysis of such systems. Primary flight surface control actuators are of particular interest because the lack of known failure data  erodes the confidence of the component and subsequently sub-system health predictions. To aid in this research, an EMA test stand has been designed and built to help in predicting the life and wear characteristics of faulted actuators with respect to their nominal counterparts. Faults are injected into the actuator during in-flight experiments while actuator parameters are recorded and then post-processed on the ground. This paper provides an assessment of the availability and reliability of the current EMA test stand design. Using the performance history of similar components in the field, this paper specifically demonstrates design aspects of the test stand that affect test system design and fault data quality. The study has been conducted to validate the test stand design, as well as offer design recommendations to increase test stand availability and ability to supply quality and robust fault to failure data sets.

How to Cite

T. Koopmans, M. ., C. Hooven, R. ., & Y. Tumer, . I. . (2010). Reliability Based Design Recommendations for an Electromechanical Actuator Test Stand. Annual Conference of the PHM Society, 2(1).
Abstract 70 | PDF Downloads 130




(Balaban, et al., 2009) E. Balaban, A. Saxena, Bansal P ., K. Goebel, P . Stoelting, and S. Curran. A Diagnostics Approach for Electro-Mechanical Actuators in Aerospace Systems, Proc. IEEE Aerospace Conference, Big Sky, MT, 2009.
(Balaban, 2009) E. Balaban, Saxena, A., Goebel, K., Byington, C., Watson, M., Bharadwaj, S., and Smith, M. Experimental Data Collection and Modeling for Nominal and Fault Conditions on Electro-Mechanical Actuators, Proc. Annual Conference of the PHM Society, San Diego, CA, 2009.
(Berenji and W ang, 2006) H. R. Berenji, and Y . W ang. Wavelet Neural Networks for Fault Diagnosis and Prognosis, Proc. IEEE International Conference on Fuzzy Systems, Vancouver, BC, Canada, 2006.
(Billinton and Allan, 1992) R. Billinton, and R. N. Allan. Reliability Evaluation of Engineering Systems: Concepts and Techniques, Plenum Press, New York, 1992.
(Bodden, et al., 2007) D. S. Bodden, S. M. Clements, B. Schley, and G. Jenney. Seeded Failure Testing and Analysis of an Electro-Mechanical Actuator, Proc. IEEE Aerospace Conference, Big Sky, MT,
(Brown, et al., 2009) D.W. Brown, G. Georgoulas, B.
Bole, H.L. Pei, M. Orchard, L. Tang, B. Saha, A. Saxena, K. Goebel, and G. V achtsevanos. Prognostics Enhanced Reconfigurable Control of Electro-Mechanical Actuators, Proc. Annual Conference of the Prognostic Health Management Society, San Diego, CA, 2009.
(Byington, et al., 2004) C. Byington, M. Watson, and D. Edwards. Data-Driven Neural Network Methodology to Remaining Life Predictions for Aircraft Actuator Components, Proc. IEEE Aerospace Conference, 2004.
(DOD, 1984) Department of Defense. Mil-Std-1629a: Procedures for Performing a Failure Mode Effects and Criticality Analysis, 1984.
(Denson, et al., 1994) W. Denson, G. Chandler, W. Crowell, A. Clark, and P. Jaworski. Nonelectric Parts Reliability Data, IIT Research Institute, New York, N.Y., 1994.
(DOD, 1991) Department of Defense, 1991, "Military Handbood - Reliability Prediction of Electronic Equipment," MIL-HDBK-217F, Washington, D.C.
(Dodsbir, 2009) Dodsbir. 2009, Predicting Faults and Determining Life of Electro-Mechanical Actuation (Ema) System for Engine and Aerospace Applications, asp?Bookmark=37477
(Dodson and Nolan, 2002) B. Dodson, and D. Nolan. Reliability Engineering Handbook, QA Publishing, Tuscon, AZ, 2002.
(Engel, et al., 2000) S.J. Engel, B.J. Gilmartin, K. Bongort, and A. Hess. Prognostics, the Real Issues Involved with Predicting Life Remaining, Proc. Aerospace Conference Proceedings, 6, pp. 457-469, 2000.
(Fuerst, et al., 2008) D. Fuerst, A. Hausberg, and T. Neuheuser. Experimental Verification of an Electro- Mechanical Actuator for a Swashplateless Primary and Individual Helicopter Blade Control System, Proc. American Helicopter Society 64th Annual Forum, Montreal, Canada, 2008.
(AIAG, 2008) Automotive Industry Action Group. Potential Failure Mode and Effects Analysis, 2008.
(Hess, et al., 2005) A. Hess, G. Calvello, and P. Frith. Challenges, Issues, and Lessons Learned Chasing The "Big P": Real Predictive Prognostics Part 1, 2005.
(Hess, et al., 2006) A. Hess, G. Calvello, P. Frith, S.J. Engel, and D. Hoitsma. Challenges, Issues, and Lessons Learned Chasing The "Big P": Real Predictive Prognostics Part 2, 2006.
(Hvass and Tesar, 2004) P.B. Hvass, and D. Tesar,Condition Based Maintenance for Intelligent Electromechanical Actuators, The University of Texas, Austin, TX, 2004
(Itemsoftware, 2007) Itemsoftware. 2007, Reliability Engineering Basics,
(Janker, et al., 2008) P. Janker, F. Claeyssen, B. Grohmann, M. Christmann, T. Lorkowski, R. Leletty, O. Sosniki, and A. Pages. New Actuators for Aircraft and Space Applications, Proc. International Conference on New Actuators, Bremen, Germany, 2008.
(Jenney, 2005) G. Jenney. Advanced Electromechanical Actuation System for Jet Blast Deflectors (Jbds), Technical Report, 2005.
(Jensen, et al., 2000) S. C. Jensen, G. D. Jenney, and D. Dawson. Flight Test Experience with an Electromechanical Actuator on the F-18 Systems Research Aircraft, Proc. IEEE Digital Avionics Systems Conference, 2000.
(Kapur and Lamberson, 1977) K.C. Kapur, and L. R. Lamberson. Reliability in Engineering Design, John Wiley and Sons, New York, 1977.
(Kiureghian, et al., 2005) A. D. Kiureghian, O. D. Ditlevsen, and J. Song. Availability, Reliability and Downtime of Systems with Repairable Components, Journal of Reliability Engineering & System Safety,2005.
(Koopmans, et al., 2009) M. Koopmans, C. Mattheis, and A Lawrence. Electro Mechanical Actuator Test Stand for in-Flight Experiments, Technical Report California Polytechnic State University, San Luis Obispo, CA, 2009.
(Koopmans and Tumer, 2010) M. Koopmans, and I.Y. Tumer. Function-Based Analysis and Redesign of a Flyable Electromechanical Actuator Test Stand, Proc. ASME IDETC/CIE, Montreal, Canada, 2010.
(Ma, 2007) L. Ma. Condition Monitoring in Engineering Asset Management, Proc. 12th Asia- Pacific Vibration Conference, Sapporo, Japan, 2007.
(Mahadevan and Smith, 2003) S. Mahadevan, and N.L. Smith. System Risk Assessment and Allocation in Conceptual Design, Technical Report, 2003.
(Modarres, et al., 1999) M. Modarres, M. Kaminskiy, and V. Krivtsov. Reliability Engineering and Risk Analysis: A Practical Guide, 1999.
(Ntsb, 1989) Ntsb, 1989, "United Airlines Flight 232 Mcdonnell Douglas Dc-10 Sioux Gateway Airport, Sioux City, Iowa, July 19,1989."
(Ntsb, 2000) Ntsb, 2000, "Aircraft Accident Report: Loss of Control and Impact with Pacific Ocean, Alaska Airlines Flight 261, Mcdonnell Douglas Md- 83, N963as, About 2.7 Miles North of Anacapa Island, California, January 31, 2000."
(O'connor, et al., 2002) P. D. T. O'connor, D. Newton, and R. Bromley. Practical Reliability Engineering, John Wiley & Sons, 2002.
(Orchard and Vachtsevanos, 2009) M.E. Orchard, and G.J. Vachtsevanos. A Particle-Filtering Approach for on-Line Fault Diagnosis and Failure Prognosis, Proc. Transactions of the Institute of Measurement and Control, 31, pp. 221-246, 2009.
(Saxena, et al., 2008) A. Saxena, J. Celaya, E. Balaban, K. Goebel, B. Saha, S. Saha, and M. Schwabacher. Metrics for Evaluating Performance of Prognostic Techniques, IEEE, ed., 2008.
(Schwabacher, et al., 2002) M. Schwabacher, J. Samuels, and L. Brownston, 2002, "The Nasa Integrated Vehicle Health Management Technology Experiment for X-37."
(Schwabacher, 2005) M. Schwabacher. A Survey of Data-Driven Prognostics, Proc. American Institute of Aeronautics and Astronautics Conference, Arlington, VA, 2005.
(Schwabacher and Goebel, 2007) M. Schwabacher, and K. Goebel. A Survey of Artificial Intelligence for Prognostics, Proc. AAAI Fall Symposium, N. A. R. Center, ed. Arlington, VA, 2007.
(Tesar and Krishnamoorthy, 2008) D. Tesar, and G. Krishnamoorthy. Intelligent Electromechanical Actuators to Modernize Ship Operations, American Society of Naval Engineers, 120(3), pp. 77-88,2008.
(Thk, 2010) Thk. 2010, Hsr-R, h.php?id=1141
(Uckun, et al., 2008) S. Uckun, K. Goebel, and P. J. F. Lucas. Standardizing Research Methods for Prognostics, IEEE, ed., 2008.
(V achtsevanos and W ang, 1999) G. V achtsevanos, and P. Wang. Fault Prognosis Using Dynamic Wavelet Neural Networks, Technical Report, 1999.
(Vachtsevanos, et al., 2006) G. Vachtsevanos, F.L. Lewis, M. Roemer, A. Hess, and B. Wu. Intelligent Fault Diagnosis and Prognosis for Engineering Systems, John Wiley & Sons, 2006.
(Vesely, et al., 1981) W.E. Vesely, F.F. Goldberg, N.H. Roberts, and D.F. Haasl. Fault Tree Handbook (Nureg-0492), 1981.
Poster Presentations