System Requirements
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Transcript System Requirements
Wireless Test Instrumentation for
Rotating Parts
ECE 193 Advisor: Rajeev Bansal
Olivia Bonner
David Vold
Brendon Rusch
Michael Grogan
ME 32 Advisor: Robert Gao
Kyle Lindell
Andrew Potrepka
Sikorsky Contacts
Company Advisor: Paul Inguanti
[email protected]
Senior Test Engineer: Chris Winslow
[email protected]
Test Instrumentation Engineer: Daniel Messner
[email protected]
Outline
Company Background
The Problem
System Requirements
2012-2013 Team Design
Design Challenges
Project Goals
Timeline
Budget
Company Background
Sikorsky Aircraft Company:
- Founded in 1925 by Igor Sikorsky in Roosevelt, NY
- Owned by United Technologies Company (UTC)
- Moved to Stratford, CT in 1929
- Produces aircraft and helicopters
- Well known models:
UH-60 Blackhawk and SH-60 Seahawk
Company Background
Produced 30 military and 10 commercial helicopters in the first
quarter of 2013
Generated $6.8 Billion [2012-2013] in net-sales
Serves 25 governments world-wide
Used in all 5 U.S. military branches
Saved close to 2 million lives since first helicopter rescue mission
in 1944
Company Background
S-92 helicopter has four blade, twin engines with a medium lift
- Used for search and rescue
S-92 aircraft elements need monitoring:
- gearboxes, control systems, rotor blades, powertrain element
The Problem
Wired sensors have several inefficiencies:
- The components are heavy
- The wires break
- The connectors fail
- Slip rings are needed for rotating components
The Problem
A wireless sensor network is a possible solution to the
problems of a wired system.
Benefits of a Wireless System:
- No long, heavy wires
- No slip rings
- Overall weight of system reduced
The Problem
Challenges of a Wireless System:
- Powering system
- Large Temperature Range
-65ºF to 400ºF
The team’s goal is to find solutions to these challenges
through research and testing.
The Problem
Figure. An interior sketch of the tail rotor gearbox on the Sikorsky S92 Helicopter.
The Problem
Figure. Exterior view of the tail rotor, (where the electrics cavity is located).
System Requirements
The team must complete the following project requirements:
- Monitor the bearing:
Temperature, Vibration, or Strain
Process the measured data:
- Fast Fourier Transform (FFT) or Band Pass Filter (BPF)
- Digitize and compress the data for storage
Temporarily store the measured data
Transmit the data to a stationary system for long term storage and
analysis
- Data must travel wirelessly upwards of 40 feet
System Requirements
Provide power to the measurement system and to the
transmitter and receiver
Figure. Illustrates the anti-bearing end of the electronics cavity.
Access is provided here.
System Requirements
Electronics Compartment:
- Size: 1.5” diameter x 5.1” long
- Temperature Range: -65ºF to 300ºF
Sensor(s):
- Minimum of 2 sensor types
- Temperature Range: -65ºF to 400ºF
Rotating Speed of Tail Rotor Shaft:
- 1200 RPM
System Requirements
Battery Life:
- 1 year min (3 years recommended)
- Must run for 12 hours a day and survive a 30 day period of
inactivity
Energy Harvesting
- Thermoelectric (Thermocouple)
- Vibrational (Piezoelectric)
- Magnetic (Alternator)
System Requirements
Environmental Parameters:
- Exterior hostile environment (maintain system internally)
- Cavity is lubricated with oil
- Moisture expected
- High vibration level expected
2012-2013 Team Design
Accelerometer, microcontroller, transceiver, and lithium battery
mounted in the electronics compartment
- One sensor
- Signal quality needs improvement
- Some components in need of replacement
Mounted on lathe-like test rig
- Bearings need replacement
2012-2013 Team Design
Figure. Test Rig from 2012-2013 team.
2012-2013 Team Design
Figure. System block diagram from 2012-2013 team.
Project Goals
ECE:
- Sensor selection (at least two different sensors)
- Signal analysis, storage, and transmission
- Ensure sufficiently clean signal
- Battery selection and power management
ME:
- Energy harvesting/energy generation to power/recharge
system
- Repair and improvement of last year’s test rig
- Mounting and installation of sensors and transmitter
Project Goals
Figure. General block diagram for 2013-2014 redesign.
6
Period Highlight:
Plan
Actual
% Complete
% Complete (beyond
plan)
Actual (beyond plan)
Timeline
Semester 2
Semester 1
February
ACTIVITY
PLAN
PLAN
ACTUAL
ACTUAL
PERCENT
START
DURATION
START
DURATION
COMPLETE
September
100%
1
4
1
4
Research
2
10
2
5
Design
8
7
Component selection
12
3
Purchasing
13
3
Prototype Build
16
8
Testing
24
5
Debugging
28
5
Final Presentations
32
4
10%
November
December
March
April
January
Weeks
1
Project Statement
October
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Budget
Budget funds from Sikorsky: $2,000
Re-use Mechanical components from last year.
Estimated Electronics costs
from last year’s expenses:
$2,129.36
Budget deficit: $129.36
Mission Questions
Which sensors should be used?
Will data processing be accomplished at the transmitter or
receiver end?
Which energy harvesting technique will be best for this
application?
What is the power envelope of the full electronics package?
Can we deliver that power through energy harvesting?
Questions?
Please vote with your iClicker based on the three
criteria:
- Grade: A, B, or C