predictive maintenance

PROGNOSTIC ENHANCED DIAGNOSTIC SYSTEM (PEDS)

Requirement needs:

  • There are limited resources to maintain critical machinery such as chillers, pumps, rotors etc.
  • There is a need to maximize equipment uptime and reduce maintenance costs
  • Current diagnostic systems lack prognostic capabilities for condition based maintenance and mission planning.
  • Cross-Platform commonality is not available

What PEDS does...

This systematic diagnostic/prognostic/CBM architecture provides an affordable and reliable means to detect impending failures predict the remaining useful lifetime of critical systems and provide confidence limits on the availability of critical mission assets.

The key benefits of a Condition-based Maintenance approach using PEDS:

  • 50% overall maintenance savings 1st year, 75% savings thereafter
  • Reduced risk
  • Increased uptime
  • Reduced maintenance personnel, need for fewer repair parts, better fuel economy, and lower repair costs
  • Intangible benefits - improved supportability, availability and reliability of equipment

PEDS generic solution

Robust & Cost Effective Generic Approach for Variety of Applications

SMART PUMPS

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BATTERY HEALTH MANAGEMENT

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CHILLER SYSTEM/HVAC PREDICTION MAINTENANCE

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HEALTH MONITORING THOUGH RFID

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advanced materials

SELF-HEALING COMPOSITES


Self healing mechanism:

FATIGUE DAMAGE ASSESMENT

Fatigue damage limits the service life of many structural components that are subjected to variable stress. Fatigue is irreversible and usually unavoidable.

High-priority objectives for preventing fatigue include containment of the fatigue damage, diagnostic tools to detect the beginnings of fatigue damage, monitoring the damage evolution during service, prognostics for reliable prediction of remnant service life, and fatigue-resistant materials by design.

The key to success for mitigating life-cycle costs is the development of fundamental understanding of fatigue damage evolution in engineered materials.

GTC performs Fatigue damage assessment for all types of metals and alloys. We have a team of professionals who have expertise in fracture mechanics, mechanical and materials technology.

advanced materials (cont)

LIFE PREDICITON OF STRUCTURES

GTC performs life prediction of structures by analyzing the capability of probabilistic strength and fatigue/fracture modeling.

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The analysis of structure involves:

  • Crack initiation, threshold and near threshold behavior
  • Methodologies for fatigue crack growth prediction
  • Load history effects and random/mission waveforms
  • Role of internal and/or residual stress on fatigue performance
  • Life prediction of structures and components
  • Fatigue under extremes of temperature and corrosive environments

 

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Life prediction of structure finds numerous applications in civil, mechanical, aerospace, and other industries. Probabilistic methods are essential for the safe and reliable design of composite these structures. The capability of probabilistic strength and fatigue/fracture modeling directly serves this need

 

FAILURE PREVENTION AND ANALYSIS

CAUSE AND ORIGIN OF FAILURE

GTC has investigated 350+ failures that included lift trucks, electrical failures, construction defects, automotive bumpers, airplane and engine component failures, automotive axle, weld joints, aluminum, titanium, polymers, ceramics and composite materials, Life assessment and durability of prototype components etc.

Some of the industries and clients that GTC serves include:

  • Automotive and transportation
  • Aerospace
  • Semiconductors and electronic materials
  • Gas and steam turbine engines
  • Chemical and chemical processing
  • Manufacturing and production
  • Heat treating, plating, welding, brazing, and thermal spray

MACHINERY AND EQUIPMENT FAILURE

GTC provides technical support for analyzing equipment and machinery failure by encompassing a wide variety of technical, managerial and business concerns.

We can provide our clients with both consultation and support in the areas of:

  • Failure analysis (component or assembly failure investigations)
  • Investigations or project work in the areas of thermal spray, HVOF coatings, plating, welding, brazing, machining (conventional and CNC), fluoride Ion cleaning, chemical striping, diffused coatings and environmental & safety
  • Gas or steam turbine engine design, engine modifications and repair development
  • Aircraft structure or component investigations
  • Quality control
  • Process substantiation (through the FAA or other agencies)
  • Process or product improvements
  • Time studies
  • Organization management
  • Technical training

Global Technology Experts can perform complete project management of multi-technical issues for industries, or take on the responsibility to solve specific problems within a technical discipline.

 

FAILURE PREVENTION AND ANALYSIS (cont)

FINITE ELEMENT AND STRESS ANALYSIS

GTC provides services in Finite Element Analysis (FEA) for engineering analysis such as Mechanics, Structural Analysis, heat transfer, fluid dynamics and electromagnetism and financial engineering. In its application, the object or system is represented by a geometrically similar model consisting of multiple, linked, simplified representations of discrete regions—i.e., finite elements on an unstructured grid.

A common use of FEA is for the determination of stresses and displacements in mechanical objects and systems. However, it is also routinely used in the analysis of many other types of problems, including those in FEA is able to handle complex systems that defy closed-form analytical solutions.

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ELECTRICAL FAILURE

GTC performs failure analysis for various types of electrical equipment such as:

  • Transformers
  • Generators
  • Aerospace electrical equipment
  • Welding machines
  • Electric motor
  • Circuit breakers

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MODELING AND SIMULATION

AFFORDABILITY MEASUREMENT AND PREDICTION SYSTEM (AMPS)

Philosophy

Provide high confidence methodology to assist in making business decisions that impact the affordability of new and current systems

Benefits:

  • Increased affordability throughout product life-cycle
  • Minimize risk
  • Provides acceptable ROI
  • Open, flexible design
  • High level of customer satisfaction

Application example:

  • A jet aircraft engine requires incorporation of new technology and manufacturing process
  • AMPS is used to identify viable design space options with costing information
  • Using all of the information provided by AMPS, a short list of flexible, economical, and feasible alternatives are selected
  • Customer makes an intelligent and informed final decision without cost over-runs and time-delays as a result of the in-depth analysis information provided by AMP

MULTIDISCIPLINARY OPTIMIZATION (MDO) AND MISSION EFFECTIVENESS

Bridging the "technology - mission" gap (ship systems)

Our Technology

GTC in Collaboration with Georgia Tech has developed an integrated framework for performing multidisciplinary optimization (MDO) of ship systems and mission effectiveness. It was developed by constructing a ‘backbone’ architecture to facilitate integration of various ship synthesis and mission effectiveness tools. This framework was based on a ‘docking’ architecture whereby individual software tools could be integrated by providing a software ‘wrapper’ around the package.

Benefits:

  • Framework that can be applied over a range of naval ship designs and missions and thus reduces cost
  • Generate accountable design information
  • The stakeholders can reach consensus more efficiently
  • The potential time reduction could be 33 %