Honeywell Aerospace Ensemble takes engine monitoring to new heights

Smart data analytics are giving business jet operators and directors of maintenance more flexibility than ever by monitoring engine performance and finding issues before they can cause surprises or even ground an aircraft. 

Advanced analytics are the driving force behind Ensemble – a game-changing addition to the renowned Maintenance Service Plan (MSP) for Honeywell Aerospace turbine engines, according to Nazar Janabi, Offering Management Leader for MSP-Propulsion.  

“Ensemble monitors engine conditions in almost real-time and automatically downloads and transmits the data after every flight, which makes it easy for maintenance teams to detect, analyze and proactively address potential issues,” he said. “It enables a preemptive approach to maintenance, reduces maintenance costs, and increases aircraft uptime and availability.” 

How Ensemble works 

Janabi uses an actual in-service example to show how Ensemble works.  

“A business aircraft not equipped with Ensemble was preparing to return home with executive passengers onboard,” he said. “The compressor on one of the engines began surging as the aircraft accelerated down the runway, so the takeoff was rejected. Subsequent inspection showed that some abradable material had detached from the compressor shroud, interfering with engine operations.”

The abradable material optimizes clearance between the compressor and the shroud, explained Systems Engineer Chris Hickenbottom. “The material is supposed to maintain its shape after initial wear-in, but in this case, it became detached and impacted engine operation.”

Ensemble could have provided the operator with advance warning of the problem, Hickenbottom continued. “The missing abradable caused a recognizable pattern in temperature, speed, fuel flow, etc., which our algorithms would have found.” 

“This pattern was detectable five flights before the rejected takeoff,” he said. “Had this aircraft been equipped with Ensemble, early warning of this condition could have been communicated to the operator, enabling them to borescope the compressor, see the missing abradable and avoid the subsequent event altogether.”

Connectivity enables Ensemble

A Wi-Fi-enabled engine data gateway is a centerpiece of Ensemble’s capabilities. It gathers data from the engines and transmits it to the Honeywell Aerospace Forge cloud-based data analytics platform over a secure connection. 

Operators can access insights and alerts using the Honeywell Aerospace Forge Engine Data Viewer and the Ensemble mobile application, which also automates data reporting requirements previously done manually. In addition, data gathered by Ensemble is used to compute the monthly rebate customers earn under the usage-based feature of Honeywell Aerospace’s MSP program, which allows operators to reduce their maintenance costs based on how the engines are being operated.

“Ensemble represents a major step forward in connectivity and advanced data analytics,” Janabi said. “We continue to work on additional features – including a soon-to-be-launched digital engine logbook – that will make MSP-Propulsion even more valuable to our customers.” 

Ensemble is now available for Bombardier Challenger 300, 350, and 3500 aircraft, Textron Longitude and Embraer Legacy and Praetor models. In 2025, it will be expanded to other aircraft, including the Dassault Falcon 900A/B.