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

∙Problem Statement ∙Solution ∙Parts Ordered ∙Parts To Be Ordered ∙Improvements To Electronics ∙Energy Harvesting Options ∙Battery Options ∙Future Tasks ∙Budget ∙Timeline Outline

● Sikorsky has asked the team to come up with a proof of concept for a wireless sensing system. ● Benefits of a Wireless System: ○ No long, heavy wires ○ No slip rings ○ Overall weight of system reduced ● Challenges of a Wireless System: ○ Powering the system ○ Large temperature range ■ -65 F to 400 F Problem Statement

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

Figure 1. System Block Diagram System Block Diagram

Figure 2. Power Circuitry Block Diagram Power Circuitry

● Sensor(s): ○ Infrared thermometer ○ Ambient thermometer ○ Accelerometer ○ Microphone ● Microcontroller: ○ Arduino Nano v3.0 ● Transceiver: ○ WiFly Module Ordered Parts

● Energy Harvesting Method ○ Brushless Generator ●Power Circuitry ○ Rectifier ○ Switching Regulator ○ Charging Circuit ● Battery ○ Lithium cells (Li-Ion, Li-Poly) Parts To Be Ordered

● Previous Design: ○ Custom built, expensive to replace/modify ○ No documentation ○ Limited connectivity ○ Missing components Improvements to Electronics ● Our Design: ○ Greater connectivity ○ Small size ○ Affordable ○ Greater available documentation

● New Custom Design: ○ Get only what we need in the size we want ○ Prohibitively expensive (cost > $1300) ○ Only can afford one ○ Little documentation ● Off the shelf options (Arduino, Teensy): ○ Excellent connectivity ○ Available in our size ○ Open sourced, excellent documentation ○ Affordable (cost < $40) Electronics Options

● Small, low power evaluation board ● Plenty of documented projects and code on website ● Many compatible sensors/add ons for sale Arduino Nano V3.0

● Triple axis accelerometer ● Electret microphone ● Ambient thermometer ● Infrared thermometer ● Low-power wifi module Sensor/Add-on Choices

● Thermoelectric  Insufficient power from available temperature gradient ● Piezoelectric  Too large  Insufficient power  Needs vibrations within a narrow range of frequencies ● Magnetic  Sufficient power  Requires low KV motor, gearing, or a step-up regulator  Necessitates use of gravitational torque Energy Harvesting Options

● NiCd and NiMH  Quick and simple charging  Durable  Poor energy density  1.2V per cell  Smaller temperature range  Memory (NiCd only) ● Lithium cells (Li-Ion, Li-Poly)  High energy density  3.7V per cell  Various shapes available (Li-Poly)  Wider temperature range  More complex charging  Less durable Battery Options

Battery Charging Circuit Options ∙Uses transistor, variable regulator, 2 capacitors, potentiometer, 1 Ohm/1 Watt resistor, 3 normal resistors Create our own:

Battery Charging Circuit Options ∙Chip Features: ∙Charger Plus Pack Protection in One IC ∙Low Operating Current (550nA) ∙Near Zero Current (<0.1nA) Low Battery Disconnect Function to Protect Batteries from Over-Discharge ∙Pin Selectable Float Voltage Options: 4.0V, 4.1V, 4.2V ∙Ultralow Power Pulsed NTC Float Conditioning for Li-Ion/Polymer Protection ∙Suitable for Intermittent, Continuous and Very Low Power Charging Sources ∙High Battery Status Output Using Power Management IC Chips:

Battery Charging Circuit Options ∙Chip Features: combines high-accuracy current and voltage regulation,battery conditioning, temperature monitoring, charge termination, charge-status indication, and AutoComp charge-rate compensation in a single 8-pin IC. Using Power Management IC Chips:

∙Different circuit – different layout inside capsule ∙Mount the rig to change pitch angle ∙Second set of wired sensors for data comparison Test Rig: Potential Modifications

Tasks for Next 45 Days ∙Assemble and test Arduino Nano with sensors ∙Assemble and test Wi-Fi module ∙Order: motors, batteries, charging circuit equipment ∙Make modifications to test rig as necessary

Budget Arduino Nano$35 Mini B USB Cable$4.50 Xbee Add-on Board$25 Wifi module$35 Nano Protoshield$15 Triple Axis Accelerometer$15 Infared Thermometer$20 Thermometer$1.50 Electret Microphone$8 DC Generator (Estimated)$20 Power Management Circuitry (Estimated)$30 Battery (Estimated)$100 Printed Circuit Board (Estimated)$200 Total$509 Purchase Breakdown ● Budget: $2,000 ● Spent to Date: $159 ● Additional Estimated Costs: $350 ● Estimated Surplus: $1,491

Timeline

Questions

Student Assessment ● Presentation Style ● Readability of Material ● Team results and deliverables are clear? Grade A, B, or C with clicker