Methods for Expanding Rotary Wing Aircraft Health and Usage Monitoring Systems to the Rotating Frame through Real-time Rotor Blade Kinematics Estimation

Since the advent of Health and Usage Monitoring Systems (HUMS) in the early 1990's, there has been a steady decrease in the number of component failure related helicopter accidents. Additionally, measurable cost benefits due to improved maintenance practices based on HUMS data has led to a desire to expand HUMS from its traditional area of helicopter drive train monitoring.;One of the areas of greatest interest for this expansion of HUMS is monitoring of the helicopter rotor head loads. Studies of rotor head load and blade motions have primarily focused on wind tunnel testing with technology which would not be applicable for production helicopter HUMS deployment, or measuring bending along the blade, rather than where it is attached to the rotor head and the location through which all the helicopter loads pass.;This dissertation details research into finding methods for real time methods of estimating rotor blade motion which could be applied across helicopter fleets as an expansion of current HUMS technology. First, there is a brief exploration of supporting technologies which will be crucial in enabling the expansion of HUMS from the fuselage of helicopters to the rotor head: wireless data transmission and energy harvesting. A brief overview of the commercially available low power wireless technology selected for this research is presented. The development of a relatively high-powered energy harvester specific to the motion of helicopter rotor blades is presented and two different prototypes of the device are shown.;Following the overview of supporting technologies, two novel methods of monitoring rotor blade motion in real time are developed. The first method employs linear displacement sensors embedded in the elastomer layers of a high-capacity laminate bearing of the type commonly used in fully articulated rotors throughout the helicopter industry. The configuration of these displacement sensors allows modeling of the sensing system as a robotic parallel mechanism, similar to a Stewart Platform. A calibration method for this device is developed and the improved orientation estimation results are shown. The second method is not specific to the fully articulated rotor head mounting geometry of the first method. Rather, it utilizes micro-electromechanical (MEMS) accelerometers and gyroscopes configured to measure the centrifugal acceleration and rotation rate induced through rotor head rotation differentially. By measuring these quantities differentially, other accelerations from the fuselage reference frame are removed from the measurement, resulting in acceleration and rate quantities that are impacted only by the angle of the sensors relative to the plane of rotation. By mounting these sensors strategically and symmetrically about the rotor blade root center of rotation, the orientation of the rotor blade can be estimated in real time.