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Based on the experiences of the Malaysian Armed Forces (MAF), failure of the main rotor gearbox (MRGB) was one of the major contributing factors to helicopter breakdowns. Even though vibration and oil analysis are the effective techniques for monitoring the health of helicopter components, these two techniques were rarely combined to form an effective assessment tool in MAF. Results of the oil analysis were often used only for oil changing schedule while assessments of MRGB condition were mainly based on overall vibration readings. A study group was formed and given a mandate to improve the maintenance strategy of S61-A4 helicopter fleet in the MAF. The improvement consisted of a structured approach to the reassessment/redefinition suitable maintenance actions that should be taken for the MRGB. Basic and enhanced tools for condition monitoring (CM) are investigated to address the predominant failures of the MRGB. Quantitative accelerated life testing (QALT) was considered in this work with an intent to obtain the required reliability information in a shorter time with tests under normal stress conditions. These tests when performed correctly can provide valuable information about MRGB performance under normal operating conditions which enable maintenance personnel to make decision more quickly, accurately and economically. The time-to-failure and probability of failure information of the MRGB were generated by applying QALT analysis principles. This study is anticipated to make a dramatic change in its approach to CM, bringing significant savings and various benefits to MAF.

Application of Vibration and Oil Analysis for Reliability Information on Helicopter Main Rotor Gearbox