1、_SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising theref
2、rom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions.Copyright 2013 SAE International All rights reserved. No part of this pub
3、lication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-4970
4、(outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/ARP6461AEROSPACERECOMMENDED PRACTICEARP6461Issued 2013-09 Guidelines for Implementat
5、ion of Structural Health Monitoring on Fixed Wing Aircraft RATIONALEThe development of Structural Health Monitoring (SHM) technologies to achieve Vehicle Health Management objectives in aerospace applications is an activity that spans multiple engineering disciplines. It is also recognized that many
6、 stakeholders i.e. Regulatory Agencies, Airlines, Original Equipment Manufacturers (OEM), Academia and Equipment Suppliers are crucial to the process of certifying viable SHM solutions. Thus a common language (definitions), framework of SHM solution approaches, and recommended practices for reaching
7、 those solutions, are needed to promote fruitful and efficient technology development. TABLE OF CONTENTS 1. SCOPE 41.1 Purpose . 41.2 Field of Application 41.3 An Overview of This Document 51.3.1 General Approach . 51.3.2 Designing and Maintaining Airworthy Structures 51.3.3 Evolution of Aircraft Pr
8、oducts Including Structures and SHM Systems . 61.3.4 Requirements, V modification of aircraft maintenance and aircraft structural health management to use and benefit from SHM systems; improving maintenance practices by utilizing alternative tools to conventional NDI; execution of scheduled and/or u
9、nscheduled maintenance tasks in a more time and cost effective manner. NOTE: Although guidance such as this may be crucial to successful implementation of an SHM system, use of this guidance alone cannot be assumed to constitute or ensure regulatory agency acceptance. Any regulatory accepted use to
10、fulfill inspection requirements will require negotiation and agreement with the appropriate regulatory agency. This SAE document is not a regulatory document and neither the applicants nor the Regulatory Agency is compelled to follow them unless there is associated Regulatory Agency policy. SAE INTE
11、RNATIONAL ARP6461 Page 5 of 95 1.3 An Overview of This Document 1.3.1 General Approach This document provides key definitions, guidelines and examples that can assist civil and military stakeholders in the development, validation, verification and certification of SHM systems. The approach adopted i
12、n developing the guidelines was to maintain harmony with existing applicable regulations, standards and guidelines, and to augment them with specific interpretations or extensions pertaining to SHM as necessary. Where existing definitions and processes were available from industry accepted publicati
13、ons, they have been adopted without modification; interpretations specific to SHM have been added for clarity. Additional definitions and processes have been collated or developed only where their equivalents did not clearly exist. In this way, consistency is maintained with existing regulations, st
14、andards and industry accepted practices. Applicable documents from which the SHM key guidelines and definitions were collated are listed in Section 2. This document does not replace any existing FARs, regulations or certification requirements currently in existence. 1.3.2 Designing and Maintaining A
15、irworthy Structures Referring to FAA publications, Section 3 reviews the main airworthiness regulations for design and maintenance of structures. Equivalent EASA regulations can be extracted from the applicable documents presented in Section 2. As summarized in Figure 1, maintenance regulations and
16、processes are introduced to overcome the threats to structural integrity, which can arise from the damaging effects of fatigue, environments and accidents. Section 3 gives more details about these regulations and processes and briefly introduces SHM. Having introduced SHM, Section 3 illustrates how
17、SHM can assist in overcoming the threats to structural integrity using existing processes without violating relevant airworthiness regulations. Section 4 describes SHM as an improved means for maintaining structural integrity and classifies potential SHM intended functions under two main headings: o
18、perational monitoring and damage detection. Operational monitoring functions maintain regular surveillance over the factors that can lead to or indicate fatigue damage (FD), environmental damage (ED) and/or accidental damage (AD). Damage detection functions directly detect FD, ED and/or AD if they o
19、ccur. Section 4 describes the outputs, potential benefits and operational considerations of SHM. Section 4 also summarizes specifications for the use of SHM systems in aircraft maintenance that have been recommended and proposed by Airlines for America Maintenance Steering Group 3 (A4A MSG-3) in rec
20、ent and pending document revisions (Revision 2009.1 and Issue Paper 105). Having described how SHM can assist in overcoming the threats to structural integrity and highlighted the A4A MSG-3 recommended specifications for SHM, the evolution phases of SHM are briefly discussed to identify the main pro
21、cesses that are recommended to approve/certify SHM systems.FIGURE 1 - DESIGNING AND MAINTAINING AIRWORTHY STRUCTURES SAE INTERNATIONAL ARP6461 Page 6 of 95 1.3.3 Evolution of Aircraft Products Including Structures and SHM Systems Figure 2 illustrates the evolution phases of any aircraft product, whi
22、ch span maturation, development, production, installation/integration, certification, utilization and maintenance. The evolution phases start with identifying intended functions that address emerging demands. The SHM technology maturation efforts are motivated by demands for improving maintenance pr
23、actices, underwriting new aircraft materials/designs and improving aircraft operational practices. Once suitable SHM technologies are identified a development process will be followed that addresses architecture, requirements, test and validation, aircraft integration and instructions for continued
24、operation. Figure 2 identifies the sections of this document, by their numbers, that provide information about these activities. FIGURE 2 - EVOLUTION OF AIRCRAFT PRODUCTS INCLUDING SHM SYSTEMSAs indicated throughout this document, any SHM system uses data acquired by on-board sensors fitted in each
25、individual aircraft to directly detect and/or monitor damage and to monitor the factors that can lead to or indicate damage. Other entities of an SHM system (for example signal conditioning and information processing subsystems) can be located on-board the aircraft or within ground-based systems. So
26、me or all of these entities may be designed specifically for SHM or can be shared entities from other pre-existing systems. Any given SHM intended function may be realized by a variety of different system architectures. 1.3.4 Requirements, V such systems may be approved by a manufacturer qualified r
27、epresentative. However, SHM systems that have major effects can be approved only by the appropriate regulator after witnessing development, validation and, verification activities conducted with rigor proportionate to the consequence of SHM failure conditions.SAE INTERNATIONAL ARP6461 Page 7 of 95 F
28、or the purpose of this document, Section 7 considers certification as the processes required for obtaining approval from the appropriate Regulatory Authority (FAA, EASA, UK MOD, DOD, etc.) that the applicable airworthiness regulations, operating rules and system requirements are met. Formal definiti
29、on of Certification taken for ARP4761 is presented in 2.3. The certification efforts involve the regulator, the product developer and the aircraft manufacturer along with any other stakeholders. The certification efforts are initiated through an application made by the aircraft OEM to the appropriat
30、e regulator, typically before the start of the product development phase; these efforts are performed in parallel to the other evolution phases and can overlap with the maturation phase. The outputs of successful certification phases include: design approval, production approval, installation approv
31、al and Instructions for Continued Airworthiness (ICA). Section 7 presents more details about the certification phases, their outputs and associated approval forms. SAE INTERNATIONAL ARP6461 Page 8 of 95 2. REFERENCES 2.1 Applicable Documents The following publications form a part of this document to
32、 the extent specified herein. The latest issue of SAE publications shall apply. The applicable issue of other publications shall be the issue in effect on the date of the purchase order. In the event of conflict between the text of this document and references cited herein, the text of this document
33、 takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained. 2.1.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724
34、-776-4970 (outside USA), www.sae.org.ARP4754 Guidelines for Development of Civil Aircraft and Systems ARP4761 Guidelines and Methods for Conducting the Safety Assessment Process on Civil Airborne Systems and EquipmentARP5150 Safety Assessment of Transport Airplanes in Commercial Service ARP5987 Esta
35、blishing Software Assurance Levels for Engine Health Management Systems utilized for Maintenance Credit (Work in Progress) 2.1.2 FAA Publications Available from Federal Aviation Administration, 800 Independence Avenue, SW, Washington, DC 20591, Tel: 866-835-5322, www.faa.gov.14CFR Part 21 Certificat
36、ion Procedures for Products and Parts 14CFR Part 23 Airworthiness Standards: Normal, Utility, Acrobatic, and Commuter Category Airplanes 14CFR Part 25 Airworthiness Standards: Transport Category Airplanes 14CFR Part 26 Continued Airworthiness and Safety Improvements for Transport Category Airplanes
37、14CFR Part 27 Airworthiness Standards: Normal Category Rotorcraft 14CFR Part 29 Airworthiness Standards: Transport Category Rotorcraft 14CFR Part 33 Airworthiness Standards: Aircraft Engines 14CFR Part 35 Airworthiness Standards: Propellers 14CFR Part 121 Operating Requirements: Domestic, Flag, and
38、Supplemental Operations 14CFR Part 135 Operating Requirements: Commuter and On Demand Operations and Rules Governing Persons On Board Such Aircraft AC 20-115 Radio Technical Commission for Aeronautic, Inc. Document RTCA DO-178 AC 20-152 RTCA, Inc., Document RTCA DO-254, Design Assurance Guidance for
39、 Airborne Electronic Hardware SAE INTERNATIONAL ARP6461 Page 9 of 95 AC 20-156 Aviation Data bus Assurance AC 25-571-1 Damage Tolerance and Fatigue Evaluation of Structure AC 25-19 Certification Maintenance Requirements AC 29-2C MG 15 Airworthiness Approval of Rotorcraft Health Usage Monitoring Syst
40、ems AC 121-22 Maintenance Review Board Report, Maintenance Type Board, and OEM/TCH Inspection EASA PublicationsFAA CPI Guide The FAA ss 21.50, 23.1529, 25.571, 25.1309, 27.1529, 29.1529, 33.4, 35.4, 121.25, 121.45, and 135.11. 3.2.3 Other Instructions for Continued Airworthiness As mentioned before,
41、 the development and approval of a MRBR is necessary but not sufficient for an OEM to comply with requirements of Appendix H to 14 CFR part 25 (Instructions for Continued Airworthiness).The complete set of Instructions for Continued Airworthiness is listed below. ICAs, like MRBR, may be affected by
42、the introduction of maintenance tasks based on SHM technologies: Airplane maintenance manual or section Includes an explanation of the airplanes features and data to the extent necessary for maintenance or preventive maintenance. A description of the airplane and its systems and installations includ
43、ing its engines, propellers, and appliances. Basic control and operation information describing how the airplane components and systems are controlled and how they operate, including any special procedures and limitations that apply. Servicing information that covers details regarding servicing poin
44、ts, capacities of tanks, reservoirs, types of fluids to be used, pressures applicable to the various systems, location of access panels for inspection and servicing, locations of lubrication points, lubricants to be used, equipment required for servicing, tow instructions and limitations, mooring, j
45、acking, and leveling information. Maintenance instructions Scheduling information for each part of the airplane and its engines, auxiliary power units, propellers, accessories, instruments, and equipment that provides the recommended periods at which they should be cleaned, inspected, adjusted, test
46、ed, and lubricated, and the degree of inspection, the applicable wear tolerances, and work recommended at these periods (normally covered by the MRBR) Information describing the order and method of removing and replacing products and parts with any necessary precautions to be taken. Diagrams of stru
47、ctural access plates and information needed to gain access for inspections when access plates are not provided Details for the application of special inspection techniques including radiographic and ultrasonic testing where such processes are specified Information needed to apply protective treatmen
48、ts to the structure after inspection All data relative to structural fasteners such as identification, discard recommendations, and torque values. A list of special tools needed SAE INTERNATIONAL ARP6461 Page 18 of 95 A section titled Airworthiness Limitations. This section must set forth: Each mand
49、atory modification time, replacement time, structural inspection interval, and related structural inspection procedure approved under 14 CFR 25.571. Each mandatory replacement time, inspection interval, related inspection procedure, and all critical design configuration control limitations approved under 14 CFR 25.981 for the fuel tank system. Any mandatory replacement time of Electrical Wiring Interc
