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. The Problem2. Project Goals3. Electrical Components4. Project Status5. Electronics Package6. Test Rig7. Budget
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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
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Wireless Test Instrumentation System for Rotating Parts
Problem
ME Team 29 - ECE Team 167Senior Design Fall 2012
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Wireless Test Instrumentation System for Rotating Parts
Problem
ME Team 29 - ECE Team 167Senior Design Fall 2012
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Wireless Test Instrumentation System for Rotating Parts
Block Diagram
ME Team 29 - ECE Team 167Senior Design Fall 2012
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Wireless Test Instrumentation System for Rotating Parts
Battery
ME Team 29 - ECE Team 167Senior Design Fall 2012
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• Battery was being tested to confirm its voltage characteristics over its lifetime
• Constant 20mA• Battery test stopped for
unknown reasons after approximately 28 days with no significant drop in voltage
• At least 13.7Ah with no voltage drop
• 10.9Ah needed to last 1 year
Battery Voltage Over First 28 days
Wireless Test Instrumentation System for Rotating Parts
Zigbee
ME Team 29 - ECE Team 167Senior Design Fall 2012
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• Zigbee has the ability to automatically append a CRC-16 to the end of the data
• Extended operation mode of Zigbee:o Automatically acknowledge receipt of data with valid
CRC byteso Automatically retry transmission of data if no
acknowledgement is received• Zigbee header takes 192µS to transmit regardless of data
rate• Data rate for the rest of the data can be adjusted up to
2Mbps• Higher data rate reduces time that the transceiver is in
transmit mode, reducing power
Wireless Test Instrumentation System for Rotating Parts
Project Status
ME Team 29 - ECE Team 167Senior Design Fall 2012
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• Completed:o Accelerometer data transmitted in real time over
Zigbeeo Accelerometer data stored in memory, and periodically
transmitted over Zigbeeo Range is approximately 40 feet
• In Progress:o Frequency analysis of accelerometer datao Improving display of datao Moving from breadboard to PCBo Final testing of PCB with test rig
Wireless Test Instrumentation System for Rotating Parts
Project Status
ME Team 29 - ECE Team 167Senior Design Fall 2012
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Accelerometer Data Display
Wireless Test Instrumentation System for Rotating Parts
Schematic
ME Team 29 - ECE Team 167Senior Design Fall 2012
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Wireless Test Instrumentation System for Rotating Parts
PCB
ME Team 29 - ECE Team 167Senior Design Fall 2012
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• PCB Dimensions are 1.3" x 2.6"
• The accelerometer is mounted on the outside of the electronics cavity and connected to the main PCB in the electronics cavity
• We had to use a 6 layer PCB due to the small size restrictions with many connections
Wireless Test Instrumentation System for Rotating Parts
PCB
ME Team 29 - ECE Team 167Senior Design Fall 2012
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Wireless Test Instrumentation System for Rotating Parts
Electronics Package
ME Team 29 - ECE Team 167Senior Design Fall 2012
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Initial Concept
Final Design
Wireless Test Instrumentation System for Rotating Parts
Test Rig
ME Team 29 - ECE Team 167Senior Design Fall 2012
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Wireless Test Instrumentation System for Rotating Parts
ME Team 29 - ECE Team 167Senior Design Fall 2012
Our budget, from Sikorsky is $4,000 and will cover the following:• Already ordered: $2655.52
Electronic Parts - $828.50 PCB - 1280.02 Mechanical Parts - $547
Bearings - $220 Bearing Mounts - $106
Collar clamp - $26 Aluminum Base - $88Shaft - $78 Hardware - $11Shaft coupler - $18
TOTAL=$2645.52 REMAINING: $1354.48
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Budget
Wireless Test Instrumentation System for Rotating Parts
ME Team 29 - ECE Team 167Senior Design Fall 2012
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Questions?
(inferior competitor's helicopter)
