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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
Wireless Test Instrumentation System for Rotating Parts
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
Wireless Test Instrumentation System for Rotating Parts
Sikorsky
ME Team 29 - ECE Team 167Senior Design Fall 2012
• 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
Wireless Test Instrumentation System for Rotating Parts
Problem
ME Team 29 - ECE Team 167Senior Design Fall 2012
• 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
Wireless Test Instrumentation System for Rotating Parts
Problem
ME Team 29 - ECE Team 167Senior Design Fall 2012
Wireless Test Instrumentation System for Rotating Parts
Problem
ME Team 29 - ECE Team 167Senior Design Fall 2012
Wireless Test Instrumentation System for Rotating Parts
Project Goals
ME Team 29 - ECE Team 167Senior Design Fall 2012
• 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
Wireless Test Instrumentation System for Rotating Parts
Block Diagram
ME Team 29 - ECE Team 167Senior Design Fall 2012
Wireless Test Instrumentation System for Rotating Parts
Wireless Transmission
ME Team 29 - ECE Team 167Senior Design Fall 2012
• 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.
Wireless Test Instrumentation System for Rotating Parts
Sensors
ME Team 29 - ECE Team 167Senior Design Fall 2012
• Temperatureo -20 to 250ºF
• Vibrationo Accelerometero Piezoelectrico ~20kHz vibration frequency
Wireless Test Instrumentation System for Rotating Parts
Microcontroller
ME Team 29 - ECE Team 167Senior Design Fall 2012
• Acquire sensor data
• Perform Fast Fourier Transform
• Data compression and storage
• Control of wireless tranceiver
• Standby mode when helicopter is not running
Wireless Test Instrumentation System for Rotating Parts
Battery
ME Team 29 - ECE Team 167Senior Design Fall 2012
• 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
Wireless Test Instrumentation System for Rotating Parts
Energy Harvesting
ME Team 29 - ECE Team 167Senior Design Fall 2012
• 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
Wireless Test Instrumentation System for Rotating Parts
Timeline
ME Team 29 - ECE Team 167Senior Design Fall 2012
Wireless Test Instrumentation System for Rotating Parts
Budget
ME Team 29 - ECE Team 167Senior Design Fall 2012
• 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
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