Development of a turbojet engine gearbox test rig for prognostics and health management

Aircraft engine gearboxes represent one of the many critical systems/elements that require special attention for longer and safer operation. Reactive maintenance strategies are unsuitable as they usually imply higher repair costs when compared to condition based maintenance. This paper discusses the main prognostics and health management (PHM) approaches, describes a newly designed gearbox experimental facility and analyses preliminary data for gear prognosis. The test rig is designed to provide full capabilities of performing controlled experiments suitable for developing a reliable diagnostic and prognostic system. The rig is based on the accessory gearbox of the GE J85 turbojet engine, which has been slightly modified and reconfigured to replicate real operating conditions such as speeds and loads. Defect to failure tests (DTFT) have been run to evaluate the performance of the rig as well as to assess prognostic metrics extracted from sensors installed on the gearbox casing (vibration and acoustic). The paper also details the main components of the rig and describes the various challenges encountered. Successful DTFT results were obtained during an idle engine performance test and prognostic metrics associated with the sensor suite were evaluated and discussed.