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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 Outline ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ Problem Statement Solution Parts Ordered Parts To Be Ordered Improvements To Electronics Energy Harvesting Options Battery Options Future Tasks Budget Timeline Problem Statement ● 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 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 Block Diagram Figure 1. System Block Diagram Power Circuitry Figure 2. Power Circuitry Block Diagram Ordered Parts ● Sensor(s): ○ Infrared thermometer ○ Ambient thermometer ○ Accelerometer ○ Microphone ● Microcontroller: ○ Arduino Nano v3.0 ● Transceiver: ○ WiFly Module Parts To Be Ordered ● Energy Harvesting Method ○ Brushless Generator ● Power Circuitry ○ Rectifier ○ Switching Regulator ○ Charging Circuit ● Battery ○ Lithium cells (Li-Ion, Li-Poly) Improvements to Electronics ● Previous Design: ○ Custom built, expensive to replace/modify ● Our Design: ○ Greater connectivity ○ Small size ○ No documentation ○ Affordable ○ Limited connectivity ○ ○ Missing components Greater available documentation Electronics Options ● ● 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) Arduino Nano V3.0 ● ● ● Small, low power evaluation board Plenty of documented projects and code on website Many compatible sensors/add ons for sale Sensor/Add-on Choices ● Triple axis accelerometer ● Electret microphone ● Ambient thermometer ● Infrared thermometer ● Low-power wifi module Energy Harvesting Options ● Thermoelectric - ● Piezoelectric - ● Insufficient power from available temperature gradient 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 Battery 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 Charging Circuit Options Create our own: ∙ Uses transistor, variable regulator, 2 capacitors, potentiometer, 1 Ohm/1 Watt resistor, 3 normal resistors Battery Charging Circuit Options Using Power Management IC Chips: ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ 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 Battery Charging Circuit Options Using Power Management IC Chips: ∙ 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. Test Rig: Potential Modifications ∙ Different circuit – different layout inside capsule ∙ Mount the rig to change pitch angle ∙ Second set of wired sensors for data comparison 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 Purchase Breakdown Arduino Nano ● ● ● ● Budget: $2,000 Spent to Date: $159 Additional Estimated Costs: $350 Estimated Surplus: $1,491 Mini B USB Cable $35 $4.50 Xbee Add-on Board $25 Wifi module $35 Nano Protoshield $15 Triple Axis Accelerometer $15 Infared Thermometer $20 Thermometer Electret Microphone $1.50 $8 DC Generator (Estimated) $20 Power Management Circuitry (Estimated) $30 Battery (Estimated) $100 Printed Circuit Board (Estimated) $200 Total $509 Timeline Questions Student Assessment ● Presentation Style ● Readability of Material ● Team results and deliverables are clear? Grade A, B, or C with clicker