SBIR-STTR Award

We propose to develop a transmission/PTM condition monitoring system concept comprised of a hierarchical distributed network of wireless sensors that sense the parameters indicative of mechanical components and system health. The project will entail determination of parameters to be sensed, hardware and software to be developed and directly address the affordability and performance issues with Figures of Merit (FOM) associated with the operation of the Advanced Amphibious Assault Vehicle, which will be in the Program Definition and Risk Reduction Phase. Collect and verify affordability FOM data. Optional Phase I risk mitigation demonstrations. Phase I will detail developments necessary to realize CBM system, set metrics for cost and affordability, identify and collect these metrics, and detail potential platform installations of the wireless smart sensor system. An option for Phase I will include a risk mitigation demonstration of a prototype wireless sensor system on a working AAAV. Important information of the wireless network performance will be detailed and optimized. Risk mitigation with the Phase I option will permit faster more efficient Phase II tasking. RF signal strengths and multipath environment quantification will also be documented in Phase I option for optimal sensor and antenna location. The CBM system offers strong potential to reduce life-cycle costs, reduce weight with wireless sensors, and increase in system performance and reliability. Affordability Figures of Merit will be generated with Phase I and Phase I option validating (or refuting) significant Return on Investment estimated to be 10:1. Condition based maintenance is one discipline that has been leveraged to curb manpower requirements through virtual presence, reduce life cycle costs by fixing only broken items, and minimize unscheduled downtime or unnecessary maintenance actions.

Benefits:
The reliability and ruggedization issues associated with traditional "dumb" sensors, cables, harness, and connectors are valid arguments for wireless smart sensors. The embedded intelligence at the sensor level provides advanced features such as power-on self-test, built-in test, digital compensation, and in-situ calibration. These advanced features eliminate false alarms and subsystem failures due to defective sensor signals. The sensor health is monitored and assessed to insure continuing proper operation. More importantly, it provides a sanity check that correct parameter information can be relied upon.

Keywords:
Condition based maintenance wireless machine-health monitoring smart-sensors accelerometers low-cost Condition based maintenance wireless machine-health monitoring smart-sensors accelerometers low-cost

We propose to develop and demonstrate the effectiveness of a wireless sensor system for Condition Based Maintenance (CBM) of the Advanced Amphibious Assault Vehicle (AAAV) for the U.S. Marine Corps deployment. Sensor data will be obtained on the AAAV Power Transfer Module (PTM) subsystem. This data will be used to develop algorithms for determining the condition of the monitored AAAV subsystem. Wireless smart sensors will be developed, miniaturized and packaged for the application. The algorithms will be hosted on the wireless smart sensors. Prototype sensors will be deployed on AAAV vehicle(s) in Phase II. Support and preparation for further AAAV deployment will be provided during the Phase II option. Phase III will focus on broad commercialization of these sensor systems and establishing manufacturing production systems.

Benefits:
In Phase I it was shown that detectin incipient failures before they occur results in significant cost avoidance. A total investment in wireless sensor systems for the AAAV PTM of $9,018,344 was shown to have the potential to save $20,730,360-$9,018,344 or $11,712,016 over the projected thirty-year life of the entire AAAV fleet. The subject sensor system is designed for this purpose. Products resulting from this research program can reduce the cost of ownership of machinery installed onboard Navy platforms, earth-moving machinery, various other military land vehicles, long-haul truck engines and transmissions, aircraft engines and locomotives.

Keywords:
Condition Based Maintenance; Smart Sensors; Machinery Maintenance; Reliability; Wireless Sensor Systems; Reduce Total Ownership Cost (TOC); Failure Anticipation; Machine Availability