Aircraft Health Monitoring Systems Seek Digital Improvements

Aircraft health monitoring systems are trending toward game-changing functionalities as they become increasingly digital and incorporate artificial intelligence and more cloud-based architectures.

“We are moving toward a world where parts that cause operational disruptions are all covered by predictive models, enabling airlines to take action before unscheduled maintenance grounds the aircraft,” says Adrien Campo, digital services marketing manager at Airbus. “We also believe that regular aircraft maintenance will soon be driven by the actual condition of aircraft parts rather than simply by a set duration or number of flight hours.”

In that regard, Campo cites A350s, which include a centralized maintenance system for diagnostics and an aircraft condition monitoring system (ACMS) with prognostic capabilities. “The ACMS processes over 20,000 operational parameters, serving as the Airbus Skywise digital platform enabler for real-time dataflow for advanced health monitoring and predictive maintenance,” he explains. “This allows for predictive interventions, streamlines line maintenance and significantly reduces unplanned downtime.”

“The aviation industry is at a pivotal point with aircraft health monitoring systems,” says Seth Babcock, head of connected aviation tech ops solutions and analytics at Collins Aerospace. “Historically, many cabin systems, such as seats, overhead bins, lighting, galleys, lavatories and other passenger-facing equipment, have been ‘dark’ from a health monitoring perspective, with little data available for predictive maintenance,” he notes. “Collins is working to change that by integrating sensors and connectivity into these cabin systems.”

Babcock adds that by capturing previously untapped data from the cabin and combining it with existing flight and propulsion system monitoring, future aircraft health monitoring systems (AHMS) can provide predictive insights, improve operational reliability and reduce unscheduled downtime.

Steve Schoonveld, connected aircraft director at GE Aerospace, predicts that AHMS will integrate on-aircraft and off-aircraft data to transition from issue identification to actionable recommendations, including when, where and why they are needed.

“The next frontier lies in advancing from fault detection to fault resolution—delivering actionable solutions within operational context. Health data will play a broader role in fleet-level optimization, directly supporting flight operations,” he says. “It will also influence aircraft leasing and financing models, where residual values are increasingly shaped by health monitoring systems.”

ARTIFICIAL INTELLIGENCE

AHMS will increasingly utilize the capabilities of artificial intelligence (AI) and cloud storage. In fact, AI is becoming a core capability of next-generation system health monitoring, says Joshua Ng, director at Alton Aviation Consultancy in Singapore.

“AI will enhance predictive analytics, fault detection and root cause analysis,” Ng says. “Over time, machine learning models trained on diverse fleet datasets will enable faster, more accurate decision-making, while reducing spurious alerts and false positives. This will further improve maintenance efficiency by directing engineering effort to the right place at the right time.”

Babcock points out that AI is expected to play a central role in future AHMS by helping automate time-consuming tasks such as data compilation, correlation and analysis. He says that AI also can provide more intuitive ways for airlines to interact with health data, identify trends and generate actionable insights. “By combining predictive analytics with pattern recognition, AI will enable faster, more accurate identification of potential issues, support proactive maintenance and help airlines make better operational decisions based on a holistic view of aircraft health,” he says.

As a case in point, GE Aerospace’s Schoonveld reports that the OEM has recently partnered with Microsoft and Accenture to develop generative AI solutions for the aviation industry. He says the first one enables airlines and lessors to access and analyze maintenance records quickly. “By integrating off-aircraft maintenance data with recorded aircraft data, these AI tools enhance fix effectiveness, identify top-performing parts and accelerate fault isolation,” he says.

CONNECTIVITY ENHANCEMENTS

As Schoonveld notes, postflight data offload still dominates, but he predicts that as connectivity becomes ubiquitous, continuous connections will enable the cloud to become the brain of the AHMS system. “A cloud-native AHMS allows tail-specific digital twins to be continuously synchronized with the aircraft,” he says. “Real-time data integrated with operational systems will facilitate moving from predicting a failure to preventing a disruption.”

In fact, low-earth-orbit (LEO) satellite constellations will enhance the capability of future AHMS to transmit, Schoonveld explains. “LEO satellite constellations will directly enhance AHMS capability by enabling continuous, secure and affordable transmission of health data,” he says. “Enhanced coverage improves AHMS data coverage because there are no legs ‘in the dark’ from monitoring. It’s more than a connectivity upgrade­—it fundamentally shifts AHMS from postflight diagnostics to inflight prescriptive decision support.”

Advances in cloud connectivity, expansion of existing data link media such as the introduction of Advanced VHF and concepts such as Hybrid Communications Networks (HYCON) with new satellite constellations (K_a/K_u)—incorporating both the safety and nonsafety media links available on an aircraft—will be among the driving forces that reshape AHMS, Babcock says. Emerging solutions, he adds, will enable smarter, event-driven data streaming in flight, with richer information pushed to the ground when anomalies occur.

“As costs per unit come down and throughput increases, cloud-based AHMS will shift from selective snapshots toward deeper, more continuous monitoring, paving the way for the expanded data transmissions,” he says. “This will allow the [Aircraft Communications Addressing and Reporting System] data link network to continue to be the driving force delivering aviation flight deck communications inclusive of [AHMS] data.”

For now, Babcock notes, one of the main challenges in aircraft health monitoring is the gap between how much data an aircraft generates and how much can realistically be recorded or transmitted.

“A Boeing 787, for example, produces on the order of 146,000 parameters across its onboard systems, many of which update multiple times per second,” he says. “This equates to millions of data points per second, yet current health monitoring practices typically record only about 3,500 parameters at 1 Hz, representing well under 1% of the total available data. Offload is also constrained, with most operators relying on cellular or Wi-Fi connections during ground turns, which limits both the volume and timeliness of data transmission.”

Emerging satellite constellations can help close this gap, Babcock says. Compared with traditional geostationary communications satellites, LEO networks provide higher throughput, lower latency and more consistent global coverage.

“This enables health monitoring systems to move from selective snapshots toward richer, event-driven data transmission in flight,” Babcock explains. “As these technologies mature, AHMS will be able to support deeper data harvesting, near-real-time anomaly detection and more robust predictive maintenance insights, without waiting until the aircraft lands.”

SYSTEMS TO WATCH

In October 2024, Honeywell Aerospace introduced Honeywell Ensemble, an aircraft-mounted engine data gateway edge note system that automates data transmission wirelessly via Wi-Fi from the engine controller unit (ECU) to the Honeywell Forge cloud and CAMP Systems software for engine health monitoring. It is included as part of Honeywell’s maintenance service plan and is available for HTF7000-series engines to automate ECU downloads, relieve workload and improve engine uptime assurance through advanced notifications, says John Head, Honeywell’s vice president and general manager for engines.

Head says the company is planning to launch a Honeywell Ensemble retrofit program for the TFE731-NG series (TFE731-20/40/60) in late 2026, to be made available through its network of channel partners. A further extension to their auxiliary power unit products is under study.

“Honeywell Ensemble enables engine gas path and [line-replaceable unit] prognostics to identify issues in advance of an operational disruption,” Head says. “By providing improved access to parameters available within the ECU, Honeywell Ensemble enables an order of magnitude increase in coverage without adding sensors.”

He adds that multiple proprietary Honeywell algorithms are being developed to use Honeywell Ensemble full flight data to address issues with anti-ice valves, guide vane actuators, surge bleed valves, engine controllers and many other components proactively.

Collins is pursuing a HYCON-based system that will connect multiple communications media into the flight deck through a common interface. The system, in the conceptual design phase, is intended to leverage all onboard media links seamlessly, Babcock says. “Collins Aerospace is helping to define how HYCON will support [aircraft health management], as well as other data, potentially extending high-throughput connectivity into existing data link networks, integrated across airlines, air navigation service providers and the broader aviation ecosystem,” he notes.