John A. Fowler & Lawrence B. Jordan

1. LOCOMOTIVES, TANKS & PREDICTIVE TELEMAINTENANCE John A. Fowler & Lawrence B. Jordan by

2. SD70MAC, 4000 HP, 1998, FIRE Gen 1 SD70MAC, 4000 HP, 1998, FIRE Gen 1 MetroLink, F59PHI, 3000 HP SD90MAC, 6000 HP, 2000

3. The Need for Failure Prediction • The Armed Services have moved from preventive maintenance initiated in the 1960’s to condition-based maintenance (CBM) started in the 1990’s. The Army’s ADIP program includes failure prediction and telemaintenance. • Electronics have been on-board locomotives since the mid-1980’s. After years of scheduled maintenance practice, a movement to CBM began in the early 1990’s with ICE followed by FIRE Gen1. FIRE Gen2 began IntelliTrain and predictive CBM conceptualization. • The IntelliTrain predictive CBM is unique in that the earliest warning is provided of an impending failure. • The IntelliTrain approach validates the PM-TMDE maintenance initiatives and inquiries are welcomed. . . . by the Earliest Warning!

4. Maintenance Goal: Reduce Cost + Increase Availability Maintenance Approaches: • Reactive – Fix when broken • Preventive – Scheduled Maintenance • Condition-Based – Fix based on current conditions • Predictive – Forecast Failure based on CBM & Experience • IntelliTrain Predictive Military CBM Initiatives • PM-TMDE: EMS/IETM, ADIP • LIA: EDAPS Gives Earliest Warning!

5. Evolution of Predictive Maintenance Preventative Reactive Predictive I know it will break someday It’s running and it’s making money It Broke Come Fix It Recommend when I should perform maintenance Help me see what needs fixing so I can plan when I will fix it High cost Low cost

6. Remote Predictive Telemaintenance • Data available, but how to gather? • Sending personnel to monitor is costly • Storing data delays prediction • Remote access is needed with security • CBM concepts in place of Preventive • To be predictive, need advanced warning • IntelliTrain Critical Success Factors (CSF): • Embedded Sensors • Secure Multi-mode Communications • Model Based Prediction • Locomotive Management Center • Maintenance Action Management

7. F 103

8. Predictive Telemaintenance Enterprise Enterprise Features & Benefits: • High Reliability Maintenance • Reduced Maintenance Cost • Limit Mean Miles Between Failure (MMBF) degradation with age • Eliminate time based overhaul • Provide 7+ days advanced warning of failure • Reduce No Defect Found (NDF) • Location of any locomotive at any time • Locomotive Control • Homeland Security Initiatives Unique featureis the creation of a personalized empirical model – each locomotive has a custom software profile.

9. Predictive Telemaintenance Enterprise

10. Remote Monitoring • Engine System • Fuel Monitor • Oil/Engine Temperature • Oil/Water Pressure • Fuel Injector Performance • Traction System • Voltage and Current • Ground Current • Vehicle Speed • Auxiliary Systems • Electronic Air Brake System • Distributed Power • Head of Train Device

11. Failure Prediction Using CBM • CBM enabled via monitoring of key feedback signals • Detect subtle system changes prior to logging faults • Water leaks • Short brush detection • Fuel oil dilution of lubricating oil • Engine performance problems • Fuel and lube oil filter plugging • Learning continues • Prediction of electrical failures • Ground current monitoring under test • Predictive Model

12. But where, on the battlefield, are they? • The location of each and every locomotive is identified by our embedded GPS. • IntelliTrain’s secure IP-Centricity provides a map with the locomotive location at any internet site. • With thousands of miles of rail, GPS location via the internet provides instant location. • Predicted failures can be planned for repair. • The same would be true to identify military vehicle location in training or on the battlefield.

13. GPS Provides Location of Locomotives Over the Internet

14. Locomotive Cab Interior View Computer/Display

15. Computer Front View Rear View Total Solution in a Single COTS Unit

16. Computer: A COTS Solution Significant Features & Benefits • System Integration (Hardware & Software) • Host for all Software (Application, drivers & OS) • Embedded BIT • Wireless control (Cellular, WLAN & GPS) • Sensor interface • Environmental protection (thermal, vibration, dust, EMI) • Thermal management (-40o C to +85o C, internal) • Fault tolerant • Future growth including homeland security

17. Computer: Remote Access Data Acquisition GPS CELLULAR CELLULAR Packet Data Circuit Switched Data DIRECT NETWORK Via WLAN Mobile Wireless Communications + GPS (COTS & custom design) Display, Controls and Power (COTS and Custom Design) LOCOMOTIVE Memory Critical Systems and Sensors System Computer And Interface Electronics (COTS Components) Legacy System & Sensors FIRE Computer

18. M1A1 The IntelliTrain Predictive CBM can benefit a wide range of military vehicles. Stryker

19. Computer Specifications • COMPUTER CHARACTERISTICS • Processor type: Intel Compatible Geode GX1-300MHz • 256 MB RAM • 128 MB Flash disk, expandable to 1 GB • Dual Ethernet & USB ports • Sound Blaster Compatible Audio Interface 2 Watts/Channel • Dual PC-104 Expansion slots • External Connections for Keyboard, Mouse, USB, Ethernet, VGA video and other PC functions • Optional Dual Channel SAE J1939 (CAN) interface • 8 External Serial Ports • 4 Isolated Synchronous/Asynchronous RS422 ports (SAE J1708) • 2 Isolated and 2 non-isolated RS232 ports

20. Computer Specifications • WIRELESS SUPPORT CHARACTERISTICS • GSM/GPRS Cellular Modem with: • Tri-band Operation (900/1800/1900 MHz) • Meets ITU Specifications • Supports GPRS class B with 56K data rates • Includes GPS • CDMA Cellular modem with: • IS 95 A CS (CDMA 1995) • 1xRTT (HSPD) IS-2000 • Supports Dual Band Operation (800/1900 MHz) • Quad Serial Interface to Single Board Computer • WLAN (IEEE 802.11b) support via Ethernet

21. Computer Specifications • ENVIRIONMENTAL CHARACTERISTICS • Temperature: • Operating: -40C to +65C • Modems: -30C to +60C • Non-operating: -50C to +71C • Humidity: • MIL-STD-810E, 95% non-condensing • Altitude: • Operating: 11,000 feet • Shock: • Operating: MIL-STD-810E, 30g • Vibration: • Random: MIL-STD-810E • EMI/EMC: • FCC Class B

22. Computer: Modem I/F Board

23. Network-Centric Multi-path Communication

24. Security • All wireless links are secured by an end-to-end Virtual Private Network (VPN). • The VPN is used on top of any additional over the air security measures such as 802.11 WEP encryption. • The VPN currently uses 128 bit encryption and strong authentication. • The VPN implementation is extensible and is capable of using 3DES, AES or other encryption standards. • No public IP addresses are used on board the locomotive. • Both ends of the connections are also fire-walled.

25. Model Based Prediction

26. Personalized Empirical Model Statistical Deviation Detection Real-time Sensor Data Determines If Operation Is Abnormal Boost Boost Diagnostic Rules Engine Real-Time Alerting of Impending Problems Eng. Rack Eng. Rack TBU RPM TBU RPM Associates Deviations with Known Problems Diagnosis How Model-Based Prediction Works Removes Effects of Normal Operation Advanced Warning Notice

27. Locomotive Management Center

28. Predictive CBM Results • No potential mission failures were detectable prior to IntelliTrain • 80% of potential mission failures were detectable via IntelliTrain prior to functional failure.

29. Future Plans • L-3/IEC – • Develop military applications: • System Integration • Communication interface • Application software • Equipment Locator • GM EMD • Expanded Suite of Remote Monitoring Solutions L3/IEC Dual Plane Display

30. Summary • Predicting Failures is as much a desire for military vehicles as for locomotives • Both military and industry have attempted to find improvements in maintenance and diagnostics. • IntelliTrain has developed a model-based predictive telemaintenance system with the following Critical Success Factors: • Embedded Sensors • Multi-mode Communications • Model-based predictive telemaintenance • Locomotive Management Center • Maintenance Action Management • Results to date: 80% of potential mission failures are detectable with the earliest warning. • L3/IEC is prepared to help any military program integrate this new form of Predictive Telemaintenance into their system.