Wireless Test Instrumentation System for Rotating Parts ECE Team 167 Lawrence Bogan Jeremy Neaton...

Wireless Test Instrumentation System for Rotating Parts

ECE Team 167Lawrence BoganJeremy Neaton

Adam BienkowskiMichael GolobME Team 29

Sean HandahlKen ThompsonCaleb Browning

Paul Inguanti - Company AdvisorChris Winslow - Senior Test Engineer

Rajeev Bansal - ECE Project AdvisorRobert Gao - ME Project Advisor


Outline

ME Team 29 - ECE Team 167Senior Design Fall 2012

1. Company Background2. The Problem3. Project Goals4. Wireless Transmission5. Sensors6. Microcontroller7. Battery8. Energy Harvesting9. Timeline10.Budget


Sikorsky


• Aircraft and helicopters• Founded 1925 by Igor Sikorsky• 1942 R-4/Hoverfly - first stable, single-rotor, fully

controllable helicopter to enter mass production, most based off this design

• Presidential transporters since 1957 - VH-3 and VH-60• Well known products - UH-60 Blackhawk and SH-60

Seahawk• 75% sales military• 29% military global market share


Problem


• Wired Sensors have some deficiencies that reduce the reliability of the systemo Wires can be heavyo Wires break, connectors fail

• Wireless Sensor Networks (WSN) solve these problems, but bring new problems to the table:o System maintenance must be minimal

• Must last for a minimum of 1 year, 3 years recommendedo Power Consumption for the system must be very low

• Battery Life and Energy Harvesting are key focal pointso WSN must operate in a noisy environment

• Proof of concept that the receiving data is the same as the transmitted data

o Packaging/Installment Issues• Entire system must fit in a 1.5" diameter by 5.1" long electronics

cavity• Packaging must protect the WSN from high vibrations,

temperatures, and condensation


Problem



Project Goals


• ECEo Sensor selection / measuring of datao Signal analysis, storage, and transmissiono Battery selection and power management

• MEo Design and creation of test rigo Energy harvesting/energy generation to

power/recharge systemo Mounting and installation of sensors and transmitter


Block Diagram



Wireless Transmission


• Wireless device must be able to transmit data over a distance of about 40 feet. The measuring system is located in the tail rotor and the stationary receiver is

located in the cabin.

• Infrared Wireless - Very weak distance travel and must have a direct line of sight

• Bluetooth - Covers up to 30 feet. It it designed for low-power simple wireless networking and supports fewer devices as well. Data can be transmitted relatively slow at times.

• Wi-fi - Consumes a lot of power and can produce too much heat. Very expensive as well.

• ZigBee - Wireless chip that is low cost and provides low power consumption and transmits data at a far distance.


Sensors


• Temperatureo -20 to 250ºF

• Vibrationo Accelerometero Piezoelectrico ~20kHz vibration frequency


Microcontroller


• Acquire sensor data

• Perform Fast Fourier Transform

• Data compression and storage

• Control of wireless tranceiver

• Standby mode when helicopter is not running


Battery


• Battery needs to last at least 1 year, Sikorsky would like it to last 3 years

• Needs to be able to work after 30 days of inactivity

• Looking into high capacity batteries that are able to fit into the cavity

• Possible batteries of interest are lithium iodide and lithium ion


Energy Harvesting


• the process of gathering extra energy to be used for power. will extend the life of the electronics

• can use thermal, vibration, or magnetic energy harvesting methods

• thermal relies on a temperature gradient. unpredictable in a helicopter due to altitude changes.

• vibration is viable and relatively constant in helicopter. turns strain into energy. energy created is relatively small. system may be too large to implement

• magnetic uses coils and a magnet to create a kind of alternator. every time the coils pass the magnet energy is generated. efficient but will needs installation on the moving parts


Timeline



Budget


• Our budget, from Sikorsky is $4,000 and will cover the following: Wireless Transmitter

Microcontroller

Sensors

Battery

Equipment for Energy Harvesting

Packaging for WSN

Representative Rotating System


Questions?


Wireless Test Instrumentation System for Rotating Parts ECE Team 167 Lawrence Bogan Jeremy Neaton...

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