SBIR-STTR Award

This proposal focuses on developing the technology critical to reducing the cost of implementing condition-based maintenance (CBM) in naval weapons platforms, by enabling low cost integration of smart load sensors into critical machinery components. The product of the investigation will be a proposed integrated diagnostic system based on embedded load measurement for a variety of CBM and other load monitoring applications. The development will focus on achieving small element size for minimum intrusion, cost effective integration with mechanical components, and will incorporate integrated processing capability. There are several reasons that acquisition of mechanical load for condition assessment is considered advantageous by comparison to more conventional CBM approaches based on acceleration (vibration) for example. Load monitoring can be employed to assess or predict a component's life expectancy whereas vibration monitoring detects imminent failure. This implies that mechanical load based CBM offers an advantage where advanced planning of maintenance is crucial. Moreover, access to real-time mechanical load data may be useful for other purposes such as overload avoidance or optimization of operating conditions. In summary, the availability of low-cost embedded load measurement and processing will enable predictive maintenance, characterization and optimization of operational conditions, overload detection and avoidance, and fatigue monitoring.

Keywords:
Condition-Based Maintenance Smart Sensors Load Sensing Prognostics And Health Management Cbm Smart M

The objective of Phase II is to develop prototype wireless Smart Bearing sensor systems in cooperation with a bearing manufacturer. The sensor is to be a low-cost component, integrated directly with a bearing. The sensor system is to be intelligent and compatible with IEEE Std 1451. This will provide an open published standard for integration of this intelligent system with any diagnostic system (e.g. ICAS). Thus, the sensor system will be a value-added adjunct to an otherwise standard bearing. Prognostic algorithms, that are characteristic of the application, will be developed and validated in conjunction with the bearing manufacturer, and predictions of Remaining Useful Life (RUL) will be correlated with results of bearing tests-to-failure. Other required developments include packaging of the sensor microelectronics, and algorithm and software integration. Load sensor prototypes will be manufactured in low volume. Documentation for the wireless sensor system prototypes also will be produced in Phase II. Power harvesting capability also will be integrated. Having this capability will cause the sensor system to be essentially maintenance-free, as well as remove the need for a separate power source, which is not always available. The coordinated sensor system electronics, powered by the integral power harvesting module, will be demonstrated as part of this contract.

Keywords:
Smart Bearing, Wireless Sensor System, Stress Pin, Bearing Test Rig, Bearing Load Sensor, Power Harvesting, Deflection Pin, Diagnostic/Prognost