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 Outline ME Team 29 - ECE Team 167 Senior Design Fall The Problem 2.Project Goals 3. Electrical Components 4. Electronics Package 5. Test Rig 6. Energy Harvesting 7. Budget 8. Timeline

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

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

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

Wireless Test Instrumentation System for Rotating Parts Project Goals ME Team 29 - ECE Team 167 Senior Design Fall 2012 ECE o Measuring of sensor data o Signal processing, storage, and transmission o Power management ME o Design and creation of test rig o Energy harvesting/energy generation to power/recharge system o Mounting and installation of sensors and transmitter

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

Wireless Test Instrumentation System for Rotating Parts Wireless Transmission ME Team 29 - ECE Team 167 Senior 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. ZigBee (Wireless chip): o Provides low power consumption o Transmits data at a far distance o Low Cost Part Number: AT86RF231 o 14 mA Active Current o.02 μA Idle Current

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

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

Wireless Test Instrumentation System for Rotating Parts Memory ME Team 29 - ECE Team 167 Senior Design Fall 2012 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: o Time synchronous averaging o Periodic Sampling o Transmit when available memory is full Cypress 16Mbit Low Power SRAM o 2mA active current o 10µA idle current

Wireless Test Instrumentation System for Rotating Parts Battery ME Team 29 - ECE Team 167 Senior Design Fall 2012 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. PartData Acquisition CurrentTransmission CurrentIdle Current Sensor11 µA0.5µA Memory2mA 22µA Microcontroller220µA 0.5µA Transceiver0.02µA14mA0.02µA Totals2.23mA16.22mA23µA

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

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

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

Wireless Test Instrumentation System for Rotating Parts Budget ME Team 29 - ECE Team 167 Senior Design Fall 2012 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=$766REMAINING: $3234

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

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