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
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Wireless Test Instrumentation System for Rotating Parts
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 - PowerPoint PPT Presentation
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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
Wireless Test Instrumentation System for Rotating Parts
Outline
ME Team 29 - ECE Team 167Senior Design Fall 2012
1. The Problem2. Project Goals3. Electrical Components4. Electronics Package5. Test Rig6. Energy Harvesting7. Budget8. Timeline
Wireless Test Instrumentation System for Rotating Parts
Problem
ME Team 29 - ECE Team 167Senior 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 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 Measuring of sensor datao Signal processing, storage, and transmissiono 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.
• ZigBee (Wireless chip):o Provides low power consumption o Transmits data at a far distanceo Low Cost
• Part Number: AT86RF231o 14 mA Active Currento .02 μA Idle Current
Wireless Test Instrumentation System for Rotating Parts
Accelerometer
ME Team 29 - ECE Team 167Senior 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 167Senior Design Fall 2012
• Needs to be able to communicate with sensor, memory and transmitter
• TI Ultra-Low Power Microcontrollero 312µA Active Currento 2.6µA Idle Currento SPI and IO interfaces
Wireless Test Instrumentation System for Rotating Parts
Memory
ME Team 29 - ECE Team 167Senior 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 averagingo Periodic Samplingo Transmit when available memory is full
• Cypress 16Mbit Low Power SRAMo 2mA active currento 10µA idle current
Wireless Test Instrumentation System for Rotating Parts
Battery
ME Team 29 - ECE Team 167Senior 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.
Part Data Acquisition Current Transmission Current Idle Current
Sensor 11 µA 0.5µA 0.5 µA
Memory 2mA 2mA 22µA
Microcontroller 220µA 220µA 0.5µA
Transceiver 0.02µA 14mA 0.02µA
Totals 2.23mA 16.22mA 23µA
Wireless Test Instrumentation System for Rotating Parts
Electronics Package
ME Team 29 - ECE Team 167Senior Design Fall 2012
Wireless Test Instrumentation System for Rotating Parts
Test Rig
ME Team 29 - ECE Team 167Senior Design Fall 2012
Wireless Test Instrumentation System for Rotating Parts
Energy Harvesting
ME Team 29 - ECE Team 167Senior 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 167Senior 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=$766 REMAINING: $3234
Wireless Test Instrumentation System for Rotating Parts
Timeline
ME Team 29 - ECE Team 167Senior Design Fall 2012
November December January February March April
Wireless Test Instrumentation System for Rotating Parts