SBIR-STTR Award

Impact Technologies, in cooperation with the MicroElectronics Department at the Rochester Institute of Technology, proposes to create a single-chip MEMS multi-sensor device capable of collecting comprehensive prognostic data. By integrating many of the sensing elements required for effective prognostic life estimation within a single tiny device, the invasiveness and expense associated with implementing condition-based maintenance practices can be dramatically reduced. The proposed MEMS-based module will record temperature, humidity, vibration/shock and stress/strain data for processing via prognostic algorithms. Key tasks of this Phase I effort include: - Design and Integration of multiple MEMS sensing elements operating in close proximity aboard a single silicon chip. - Development of signal conditioning circuitry tailored for driving and recording data from the prognostic MEMS sensing system. - Optimizing power usage based on data sampling rate and duration required for each specific application. - Creating an overall package design that encompasses the sensor, electronics, and communications in form factor that can be noninvasively deployed aboard most platforms. In phase I, a prototype MEMS sensor will be fabricated and parameter sensing will be verified. This provides the groundwork for the development of a deployable, near-final-scale prototype module in Phase II.

Benefit:
The proposed PRISM module provides a cost-effective means of attaining the data required to make accurate equipment Prognostics Health Management calculations. The miniaturized PRISM module allows for non-invasive installation aboard any mechanical platform rotorcraft, fixed wing aircraft, ground vehicles and stationary equipment. The generic data these sensors take is useful for tracking health of many subsystems, from powertrains to avionics. PHM applications include: - Any type of vehicle fleet: aircraft, heavy construction, locomotives, public transportation, tractor trailers, etc. - Maintaining leased automobiles (ensuring up time). - Remote unmanned equipment, such as pump stations and electrical distribution equipment. The basic MEMS sensor platform will be useful beyond PHM applications. Examples include: - A shipping checker that tracks how a package was handled during shipping - Temporary Stick-on sensors for equipment tests - Inclusion in consumer electronics (e.g. cell phones) for measuring ambient environments - Environmental control in HVAC systems and greenhouses

Keywords:
MEMS, MEMS, Condition-based maintenance, temperature, strain, Vibration, Rotorcraft, humidity, Prognostic Sensor

Impact Technologies, in cooperation with the MicroElectronics Department at the Rochester Institute of Technology, are creating an ultra-small sensing system for measuring temperature, relative humidity and shock for use in prognostic applications. The long term II goal is to create a device that is smaller than a penny. This will enable collecting comprehensive usage data in areas where data collection was previously not possible. Of special note is measurement within critical electronic systems such as JCREW. The gated Phase II program is designed to show working sensor system size reductions - to very close to penny size, and ultimately to penny size at the end of Phase II. Key aspects of the Phase II effort include: - Integration of updated Phase I MEMS sensors with onboard embedded digital electronics to reach near-penny size(but slightly taller) showing the basic electronics design is appropriate. - Incorporating the 2nd and 3rd axes of shock and decreasing height of system to penny size by using aggressive electronics packaging concepts. In Phase II, penny-sized prototype sensors will be fabricated and parameter sensing will be verified. This provides the groundwork for application studies of near-commercial prototypes in follow-on Phase III field trials.

Benefit:
The PRISM sensing system will provide a cost-effective means of attaining the environmental and health data required to make accurate Prognostics Health Management calculations. The miniaturized system permits minimally invasive installation onboard many platform types rotorcraft, fixed wing aircraft, ground vehicles, stationary equipment and critical electronics. Applications would include any type of vehicle fleet: aircraft, heavy construction, public transportation, tractor trailers, etc. The miniature form factor, however, makes the system an ideal enabler for ensuring the health of critical electronics, such as radio jammers, avionics, control systems, servers - places and systems where raw data for PHM have not typically been available. Other examples of useful applications of the system include: A shipping checker that tracks how cargo was handled during shipping and low-profile environmental tracking in HVAC systems and greenhouses.

Keywords:
Shock, Rotorcraft, Condition-based maintenance, humidity, MEMS, temperature, Prognostic Sensor