Demonstration and Validation of Stable and Highly-Reliable Harsh EnvironmentWireless SAW Sensors in OEM Turbine Engine

ABSTRACT:The U.S. Air Force (USAF) and the aerospace industry have a critical need for reliable harsh-environment sensors that can deliver real-time monitoring in a turbine engine environment. During Phase I, Environetix confirmed that most harsh environment technologies that rely on wired sensors or complicated wireless hybrid systems have their reliability compromised by the wires or the connection complexity. Also as part of the Phase I effort, Environetix leveraged its extensive experience in high temperature sensor materials, devices, packaging, and data acquisition, to verify through thermal cycling and maximum temperature tests up to 1000C in laboratory furnaces that the core of its patented technology, the prototype wireless surface acoustic wave (SAW) langasite (LGS) temperature sensor presents stability comparable or better than the thermocouples used as reference. During the Phase II period, Environetix will partner with Pratt & Whitney (P&W), and further improve sensor/antenna connections and packaging in order to validate the wireless LGS SAW sensor technology in P&W laboratories for TRL 4 confirmation, followed by tests in a P&W turbine engine test cell for TRL 6 validation. The Phase II results will allow Environetix and P&W to establish a roadmap for the wireless SAW Environetixs sensor technology commercialization.BENEFIT:Environetixs harsh-environment wireless battery-free small-profile sensors capable of reaching temperatures over 1000C (1830oF) will have a major impact on the aerospace industry by providing the following benefits in turbine engine monitoring: (i) Reliable operation for several thousands of hours or more, and easily reaching the minimum 4,000 hrs operation in hot sections for test cell applications; (ii) Validation of engine modeling and operational conditions by wirelessly monitoring engine conditions at locations not possible by other sensor technologies; (iii) Verification of integrity of seals, shrouds, and other critical engine locations, due to both small size and wireless sensor operation: (iv) Removal of wires to deliver the required sensing information, thus saving significant costs in manpower (sensor installation in the turbine), reduced weight, and simultaneously improving performance and reliability, since wires are a well-known cause of sensor early failure; and (v) Through more reliable temperature monitoring, provide better engine performance, improved fuel efficiency, and increased power at reduced engine operation (or flight) costs. The wireless SAW sensor technology also has many commercial applications in other sectors such a power generation, oil/gas exploration, manufacturing process control, and other high temperature harsh environment processes.