How Honeywell Ensemble Uses AI to Predict Engine Health

Modern turbofan aircraft engines generate a lot of data about the engine’s performance and condition. The trick comes in turning those terabytes of data into actionable information directors of maintenance can use to head off problems that could impact safety or disrupt normal operations. 

The recent emergence of artificial intelligence changed the engine maintenance process forever. AI can analyze vast amounts of data in almost real time, predict when engine components are likely to fail and enable technicians to perform maintenance before serious issues arise. AI takes predictive maintenance to a whole new level, improves engine assurance and reliability, and helps reduce total maintenance costs.

In an enormous leap forward, Honeywell is pioneering the use of AI with Honeywell Ensemble, our new digital maintenance service. Honeywell Ensemble is integrated with our industry-leading Maintenance Service Plan (MSP), which has been protecting operators from unplanned engine downtime and maintenance budget surprises for almost 50 years. 

Meet the Power Behind Honeywell Ensemble

Honeywell Ensemble continuously monitors and records engine performance data. It tracks engine parameters including vibration, inter-turbine temperature, engine pressures, fuel consumption, and many other parameters in search of anomalies that can foresee  future maintenance issues.

Data is aggregated and analyzed by a sophisticated EngineCompressorAI algorithm, which represents the true power behind Honeywell Ensemble. The algorithm uses predictive analytics to identify potential issues and alert maintenance teams so they can repair or replace engine components before they cause operational disruptions.

After every flight, engine performance information is autonomously transmitted to the Honeywell Forge data analytics platform and CAMP, Honeywell’s engine health monitoring partner, for further analysis and tracking. A Wi-Fi-enabled Honeywell engine data gateway installed on the aircraft makes this possible. 

The information is available to operators almost immediately so it can be reviewed on the Honeywell Forge Engine Data Viewer and the Honeywell Ensemble mobile application. From there, the operators can schedule any required maintenance or develop a plan to monitor potential faults. 

By leveraging AI, Honeywell Ensemble builds on the acknowledged power of predictive and prescriptive maintenance. It lets technicians diagnose problems sooner, improve aircraft performance and uptime, and reduce maintenance costs

Proving the Case for MSP and Honeywell Ensemble

An actual incident involving an aircraft covered under another maintenance plan demonstrates the value of Honeywell Ensemble powered by the EngineCompressorAI Algorithm.

A mid-size business jet was preparing for takeoff when it experienced a compressor surge in one engine. A compressor surge is a temporary loss of power associated with unstable airflow through the compressor, which can be caused by component wear or a mechanical system failure.

In this case the engine surge caused violent vibrations, alarmed passengers with loud banging and resulted in a sudden rejection of the takeoff by the pilot. 

While the aircraft was not covered by Honeywell MSP, as the engine manufacturer we examined the engine data and learned a few details about the incident. CAMP detected potential problems almost 10 weeks before the incident and recommended the compressor be examined with a borescope within 200 flying hours. 

The maintenance plan provider denied the borescope inspection, which could have uncovered the compressor issue that eventually caused the compressor to surge. This resulted in the aircraft being out commission for an extended period. 

If the aircraft had been enrolled in MSP, Honeywell Ensemble would have detected the issue when it originated, which would have validated the need for a borescope. The test results would have identified the fault and provided us with the information needed to repair the engine and avoid the surging incident altogether. 

Aircraft downtime could have been minimized, and the cost of the borescope inspection and engine repairs would have been covered by Honeywell MSP.  

Exciting advancements like Honeywell Ensemble and the EngineCompressorAI Algorithm demonstrate the constant evolution of MSP-Propulsion, which makes the plan more valuable for our customers. 

We would like to tell you how MSP can help your operation increase aircraft availability, enhance mission assurance and reduce operational disruption and passenger inconvenience. 

Contact your Honeywell representative or visit us online to learn more.