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. Project Status 5. Electronics Package 6. Test Rig 7. Budget 2/17

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 3/17

Wireless Test Instrumentation System for Rotating Parts Problem ME Team 29 - ECE Team 167 Senior Design Fall /17

Wireless Test Instrumentation System for Rotating Parts Problem ME Team 29 - ECE Team 167 Senior Design Fall /17

Wireless Test Instrumentation System for Rotating Parts Block Diagram ME Team 29 - ECE Team 167 Senior Design Fall /17

Wireless Test Instrumentation System for Rotating Parts Battery ME Team 29 - ECE Team 167 Senior Design Fall /17 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 167 Senior Design Fall /17 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 bytes o 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 167 Senior Design Fall /17 Completed: o Accelerometer data transmitted in real time over Zigbee o Accelerometer data stored in memory, and periodically transmitted over Zigbee o Range is approximately 40 feet In Progress: o Frequency analysis of accelerometer data o Improving display of data o Moving from breadboard to PCB o Final testing of PCB with test rig

Wireless Test Instrumentation System for Rotating Parts Project Status ME Team 29 - ECE Team 167 Senior Design Fall /17 Accelerometer Data Display

Wireless Test Instrumentation System for Rotating Parts Schematic ME Team 29 - ECE Team 167 Senior Design Fall /17

Wireless Test Instrumentation System for Rotating Parts PCB ME Team 29 - ECE Team 167 Senior Design Fall /17 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 167 Senior Design Fall /17

Wireless Test Instrumentation System for Rotating Parts Electronics Package ME Team 29 - ECE Team 167 Senior Design Fall /17 Initial Concept Final Design

Wireless Test Instrumentation System for Rotating Parts Test Rig ME Team 29 - ECE Team 167 Senior Design Fall /17

Wireless Test Instrumentation System for Rotating Parts ME Team 29 - ECE Team 167 Senior Design Fall 2012 Our budget, from Sikorsky is $4,000 and will cover the following: Already ordered: $  Electronic Parts - $  PCB  Mechanical Parts - $547 Bearings - $220Bearing Mounts - $106 Collar clamp - $26Aluminum Base - $88 Shaft - $78Hardware - $11 Shaft coupler - $18 TOTAL=$ REMAINING: $ /17 Budget

Wireless Test Instrumentation System for Rotating Parts ME Team 29 - ECE Team 167 Senior Design Fall /17 Questions? (inferior competitor's helicopter)