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
pinguanti@sikorsky.com
 Senior Test Engineer: Chris Winslow
cwinslow@sikorsky.com
 Test Instrumentation Engineer: Daniel Messner
daniel.messner@sikorsky.com
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