Shift5, a Navy, defense and aerospace technology company, has won a major contract to test predictive maintenance technology for the V-22 Osprey helicopter. The technology aims to prevent gearbox failures, which have been a leading cause of fatal accidents in recent years. Under Shift5’s contract with NAVAIR, the U.S. Navy’s air systems command, the Marine Corps’ operational test squadron will test the company’s manifold technology on Ospreys.
Technology and Purpose
“Given the importance of resolving life-threatening issues that occur in the V-5, we aim to increase crew situational awareness by providing real-time information,” Shift22 CEO Josh Lospinoso said in a statement about the technology. The technology is specifically aimed at helping understand a problem called “hard coupling interactions.” Hard coupling interactions are brief periods of slippage between the Osprey’s engine and the point where its propeller attaches to the rotor gearbox. This can cause the aircraft to shake and, in some cases, damage components that can lead to fatal crashes.
V-22 Osprey Problems and Accidents
These types of hard-clutch interactions have previously led to multiple Osprey crashes. For example, a crash in Southern California in June 2022 killed five Marines and was also linked to a hard-clutch crash. In November 2023, a CV-22B Osprey crash off the coast of Japan killed eight airmen. The crashes were attributed to a critical failure in the Osprey’s gearbox.
Predictive Maintenance and Data Collection
Shift5’s technology is expected to collect more data on these types of interactions, allowing for early detection of potential hazards. This will allow maintenance teams to take action faster and flight crews to be warned in advance. Shift5’s device will provide this data to the flight crew via a “manifold device” that will be integrated into the aircraft’s data collection system, Lospinoso said. The device will help reduce human error by collecting vibrations and other critical data within the transmission and reminding flight crews during flight.
Future Steps
Shift5’s device is currently being tested only by the Joint Program Office, but the company aims to integrate the technology into all Army Ospreys in the future. This will require a phased approach that involves installing the devices during maintenance on Ospreys. Shift5 and the Army plan to continue working toward full fielding of the device next quarter, the company said.
This Shift5 solution has great potential in terms of both safety and maintenance efficiency. This innovative technology for the maintenance and safety processes of the V-22 Osprey could make a significant difference to military operations in the long term.
