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Wireless Test Instrumentation System for Rotating Parts. ECE Team 167 Lawrence Bogan Jeremy Neaton Adam Bienkowski Michael Golob ME Team 29 Sean Handahl Ken Thompson Caleb Browning. Paul Inguanti - Company Advisor Chris Winslow - Senior Test Engineer Rajeev Bansal - ECE Project Advisor
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Wireless Test Instrumentation System for Rotating Parts ECE Team 167 Lawrence Bogan Jeremy Neaton Adam Bienkowski Michael Golob ME Team 29 Sean Handahl Ken Thompson Caleb Browning Paul Inguanti - Company Advisor Chris Winslow - Senior Test Engineer Rajeev Bansal - ECE Project Advisor Robert Gao - ME Project Advisor
Wireless Test Instrumentation System for Rotating Parts 2/17 Outline • 1. The Problem • 2. Project Goals • 3. Electrical Components • 4. Project Status • 5. Electronics Package • 6. Test Rig • 7. Budget ME Team 29 - ECE Team 167 Senior Design Fall 2012
Wireless Test Instrumentation System for Rotating Parts 3/17 Problem • Collect and wirelessly transmit data pertaining to the tail rotor pitch change bearing in S-92 helicopter • Wireless link to eliminate need for wired interface between rotating and non-rotating parts • Battery must last at least 1 year, 3 years recommended • Electronics cavity is 1.5" diameter by 5.1" long • Components will be in a noisy environment with high vibrations and temperature ME Team 29 - ECE Team 167 Senior Design Fall 2012
Wireless Test Instrumentation System for Rotating Parts 4/17 Problem ME Team 29 - ECE Team 167 Senior Design Fall 2012
Wireless Test Instrumentation System for Rotating Parts 5/17 Problem ME Team 29 - ECE Team 167 Senior Design Fall 2012
Wireless Test Instrumentation System for Rotating Parts 6/17 Block Diagram ME Team 29 - ECE Team 167 Senior Design Fall 2012
Wireless Test Instrumentation System for Rotating Parts 7/17 Battery • Battery was being tested to confirm its voltage characteristics over its lifetime • Constant 20mA • Battery test stopped for unknown reasons after approximately 28 days with no significant drop in voltage • At least 13.7Ah with no voltage drop • 10.9Ah needed to last 1 year Battery Voltage Over First 28 days ME Team 29 - ECE Team 167 Senior Design Fall 2012
Wireless Test Instrumentation System for Rotating Parts 8/17 Zigbee • Zigbee has the ability to automatically append a CRC-16 to the end of the data • Extended operation mode of Zigbee: • Automatically acknowledge receipt of data with valid CRC bytes • Automatically retry transmission of data if no acknowledgement is received • Zigbee header takes 192µS to transmit regardless of data rate • Data rate for the rest of the data can be adjusted up to 2Mbps • Higher data rate reduces time that the transceiver is in transmit mode, reducing power ME Team 29 - ECE Team 167 Senior Design Fall 2012
Wireless Test Instrumentation System for Rotating Parts 9/17 Project Status • Completed: • Accelerometer data transmitted in real time over Zigbee • Accelerometer data stored in memory, and periodically transmitted over Zigbee • Range is approximately 40 feet • In Progress: • Frequency analysis of accelerometer data • Improving display of data • Moving from breadboard to PCB • Final testing of PCB with test rig ME Team 29 - ECE Team 167 Senior Design Fall 2012
Wireless Test Instrumentation System for Rotating Parts 10/17 Project Status Accelerometer Data Display ME Team 29 - ECE Team 167 Senior Design Fall 2012
Wireless Test Instrumentation System for Rotating Parts 11/17 Schematic ME Team 29 - ECE Team 167 Senior Design Fall 2012
Wireless Test Instrumentation System for Rotating Parts 12/17 PCB • PCB Dimensions are 1.3" x 2.6" • The accelerometer is mounted on the outside of the electronics cavity and connected to the main PCB in the electronics cavity • We had to use a 6 layer PCB due to the small size restrictions with many connections ME Team 29 - ECE Team 167 Senior Design Fall 2012
Wireless Test Instrumentation System for Rotating Parts 12/17 PCB ME Team 29 - ECE Team 167 Senior Design Fall 2012
Wireless Test Instrumentation System for Rotating Parts 13/17 Electronics Package Final Design Initial Concept ME Team 29 - ECE Team 167 Senior Design Fall 2012
Wireless Test Instrumentation System for Rotating Parts 14/17 Test Rig ME Team 29 - ECE Team 167 Senior Design Fall 2012
Wireless Test Instrumentation System for Rotating Parts 15/17 Budget Our budget, from Sikorsky is $4,000 and will cover the following: • Already ordered: $2655.52 • Electronic Parts - $828.50 • PCB - 1280.02 • Mechanical Parts - $547 Bearings - $220 Bearing Mounts - $106 Collar clamp - $26 Aluminum Base - $88 Shaft - $78 Hardware - $11 Shaft coupler - $18 TOTAL=$2645.52 REMAINING: $1354.48 ME Team 29 - ECE Team 167 Senior Design Fall 2012
Wireless Test Instrumentation System for Rotating Parts 17/17 Questions? (inferior competitor's helicopter) ME Team 29 - ECE Team 167 Senior Design Fall 2012