Wireless Test Instrumentation System for Rotating Parts

1. 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

2. Wireless Test Instrumentation System for Rotating Parts Outline • Company Background • The Problem • Project Goals • Wireless Transmission • Sensors • Microcontroller • Battery • Energy Harvesting • Timeline • Budget ME Team 29 - ECE Team 167 Senior Design Fall 2012

3. Wireless Test Instrumentation System for Rotating Parts 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 ME Team 29 - ECE Team 167 Senior Design Fall 2012

4. Wireless Test Instrumentation System for Rotating Parts Problem • Wired Sensors have some deficiencies that reduce the reliability of the system • Wires can be heavy • Wires break, connectors fail • Wireless Sensor Networks (WSN) solve these problems, but bring new problems to the table: • System maintenance must be minimal • Must last for a minimum of 1 year, 3 years recommended • Power Consumption for the system must be very low • Battery Life and Energy Harvesting are key focal points • WSN must operate in a noisy environment • Proof of concept that the receiving data is the same as the transmitted data • 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 ME Team 29 - ECE Team 167 Senior Design Fall 2012

5. Wireless Test Instrumentation System for Rotating Parts Problem ME Team 29 - ECE Team 167 Senior Design Fall 2012

6. Wireless Test Instrumentation System for Rotating Parts Problem ME Team 29 - ECE Team 167 Senior Design Fall 2012

7. Wireless Test Instrumentation System for Rotating Parts Project Goals • ECE • Sensor selection / measuring of data • Signal analysis, storage, and transmission • Battery selection and power management • ME • Design and creation of test rig • Energy harvesting/energy generation to power/recharge system • Mounting and installation of sensors and transmitter ME Team 29 - ECE Team 167 Senior Design Fall 2012

8. Wireless Test Instrumentation System for Rotating Parts Block Diagram ME Team 29 - ECE Team 167 Senior Design Fall 2012

9. Wireless Test Instrumentation System for Rotating Parts 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. ME Team 29 - ECE Team 167 Senior Design Fall 2012

10. Wireless Test Instrumentation System for Rotating Parts Sensors • Temperature • -20 to 250ºF • Vibration • Accelerometer • Piezoelectric • ~20kHz vibration frequency ME Team 29 - ECE Team 167 Senior Design Fall 2012

11. Wireless Test Instrumentation System for Rotating Parts Microcontroller • Acquire sensor data • Perform Fast Fourier Transform • Data compression and storage • Control of wireless tranceiver • Standby mode when helicopter is not running ME Team 29 - ECE Team 167 Senior Design Fall 2012

12. Wireless Test Instrumentation System for Rotating Parts 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 ME Team 29 - ECE Team 167 Senior Design Fall 2012

13. Wireless Test Instrumentation System for Rotating Parts 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 ME Team 29 - ECE Team 167 Senior Design Fall 2012

14. Wireless Test Instrumentation System for Rotating Parts Timeline ME Team 29 - ECE Team 167 Senior Design Fall 2012

15. Wireless Test Instrumentation System for Rotating Parts 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 ME Team 29 - ECE Team 167 Senior Design Fall 2012

16. Wireless Test Instrumentation System for Rotating Parts Questions? ME Team 29 - ECE Team 167 Senior Design Fall 2012