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Spall Fault Quantification Method for Flight Control Electromechanical Actuator

Ismail, Mohamed AA and Balaban, Edward and Windelberg, Jens (2022) Spall Fault Quantification Method for Flight Control Electromechanical Actuator. Actuators, 11 (29). Multidisciplinary Digital Publishing Institute (MDPI). doi: 10.3390/act11020029. ISSN 2076-0825.

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Flight control electro-mechanical actuators (EMAs) are among the primary onboard systems that significantly influence the reliability and safety of unmanned aerial vehicles. Recent reliability studies have shown that the ball-screw element of a flight control EMA is subject to oscillating operating conditions that may initiate rapid degradation, such as fatigue spall defects. Accordingly, detecting and quantifying such faults are crucial for developing efficient fault prognostic and remaining useful life estimation capabilities. In this study, a vibration-based fault quantification method is developed to quantify the fatigue faults of a ball-screw mechanism of an EMA. The method is based on identifying the ball passing instants through a localized surface defect on the vibrational jerk rather than the vibrational acceleration measurement. The jerk is numerically determined from conventional accelerometers using a Savitzky–Golay differentiator. This method was successfully tested for ball bearings and it is adjusted in this paper for ball-screw faults. The experimental validation is investigated on a set of fault-seeded samples on NASA’s Ames Research Center Flyable Electro-Mechanical Actuator test stand.

Item URL in elib:https://elib.dlr.de/191732/
Document Type:Article
Title:Spall Fault Quantification Method for Flight Control Electromechanical Actuator
AuthorsInstitution or Email of AuthorsAuthor's ORCID iDORCID Put Code
Ismail, Mohamed AAUNSPECIFIEDhttps://orcid.org/0000-0002-2077-0681UNSPECIFIED
Windelberg, JensUNSPECIFIEDhttps://orcid.org/0000-0002-9249-2967UNSPECIFIED
Date:20 January 2022
Journal or Publication Title:Actuators
Refereed publication:Yes
Open Access:Yes
Gold Open Access:Yes
In ISI Web of Science:Yes
Publisher:Multidisciplinary Digital Publishing Institute (MDPI)
Keywords:flight control surface; Savitzky-Golay differentiator; spall size estimation; rolling contact fatigue; vibrational jerk
HGF - Research field:Aeronautics, Space and Transport
HGF - Program:Aeronautics
HGF - Program Themes:Components and Systems
DLR - Research area:Aeronautics
DLR - Program:L CS - Components and Systems
DLR - Research theme (Project):L - Aircraft Systems
Location: Braunschweig
Institutes and Institutions:Institute of Flight Systems
Institute of Flight Systems > Safety Critical Systems&Systems Engineering
Deposited By: Ismail, Dr. Mohamed AA
Deposited On:19 Jan 2023 14:22
Last Modified:19 Oct 2023 13:54

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