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 • The Problem • Project Goals • Electrical Components • Electronics Package • Test Rig • Energy Harvesting • Budget • Timeline ME Team 29 - ECE Team 167 Senior Design Fall 2012

3. Wireless Test Instrumentation System for Rotating Parts 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

4. Wireless Test Instrumentation System for Rotating Parts Problem 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 Project Goals • ECE • Measuring of sensor data • Signal processing, storage, and transmission • 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

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

8. 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. • ZigBee (Wireless chip): • Provides low power consumption • Transmits data at a far distance • Low Cost • Part Number: AT86RF231 • 14 mA Active Current • .02 μA Idle Current ME Team 29 - ECE Team 167 Senior Design Fall 2012

9. Wireless Test Instrumentation System for Rotating Parts Accelerometer • The accelerometer needs to transmit the vibration data it receives to the microcontroller. • Accelerometer needed to have an interrupt. This will tell the microcontroller when to start recording the data. • Our sensor needed a minimum bandwidth of 400Hz, so we found an accelerometer with an adjustable bandwidth in that range. • The power consumption needed to be at a minimum. We were able to find an accelerometer with an active current of 11μA. • This sensor is extremely small at 3 x 3 mm. LIS3DH ME Team 29 - ECE Team 167 Senior Design Fall 2012

10. Wireless Test Instrumentation System for Rotating Parts Microcontroller • Needs to be able to communicate with sensor, memory and transmitter • TI Ultra-Low Power Microcontroller • 312µA Active Current • 2.6µA Idle Current • SPI and IO interfaces ME Team 29 - ECE Team 167 Senior Design Fall 2012

11. Wireless Test Instrumentation System for Rotating Parts Memory • Needed to store sensor data • If data is collected continuously over the maximum specified time of 12 hours between data accesses, this will produce too much data to store and transmit given power and space constraints • Options: • Time synchronous averaging • Periodic Sampling • Transmit when available memory is full • Cypress 16Mbit Low Power SRAM • 2mA active current • 10µA idle current ME Team 29 - ECE Team 167 Senior Design Fall 2012

12. Wireless Test Instrumentation System for Rotating Parts Battery • Assuming constant sampling, transmission when memory is full, 16-bit samples, 1.25kHz sampling rate: Total battery capacity needed is 10.5Ah • We found a lithium thionyl chloride battery, The Tadiran 5930 battery has 17Ah. ME Team 29 - ECE Team 167 Senior Design Fall 2012

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

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

15. Wireless Test Instrumentation System for Rotating Parts Energy Harvesting • Unnecessary to meet minimum design requirements, but will extend the life of the electronics past one year. • Researched thermal, vibration, or magnetic energy harvesting methods • Vibration is the only viable and relatively constant in helicopter; turns strain into energy, energy created is relatively small, and the system may be too large to implement • A custom rectifier board is needed: commercial boards are too large. If we cannot make a custom board we cannot use energy harvesting. Energy output is dependent on how much space is left for the unit to vibrate. ME Team 29 - ECE Team 167 Senior Design Fall 2012

16. Wireless Test Instrumentation System for Rotating Parts Budget • Our budget, from Sikorsky is $4,000 and will cover the following: • Wireless Transmitter- $5 • Microcontroller- $10 • Sensors- $2 • Battery- $25 • Memory- $16 • Antenna- $8 • PCB- ~$100 • Energy Harvester and Equipment- ~$100 • Representative Rotating System- ~$500 TOTAL=$766 REMAINING: $3234 ME Team 29 - ECE Team 167 Senior Design Fall 2012

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

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