MEMS-Based Intelligent Gearbox Condition Monitoring System

To address the Navy’s need for a system capable of winch gearbox prognostics and health management, Physical Optics Corporation (POC) proposes to develop a new MEMS-Based Intelligent Gearbox Condition Monitoring (MIGCOM) system. This proposed MIGCOM system is based on multisensor data fusion and a model-based prognostic algorithm. The innovation in the new design of wireless MEMS sensors, novel hard coating on MEMS, and new design of model-based prognostic software will enable the MIGCOM to realize wireless reliable prediction of the remaining life of a winch gearbox. This system thus offers small size, low cost, light weight, and capability to survive the harsh maritime environment, which directly addresses the Navy PMA-299, H-60 Helicopter, and Sea Shield acquisition program requirements. In Phase I, POC will demonstrate the feasibility of MIGCOM by developing the system design and analyzing its functionality and suitability for relevant aircraft environments. In Phase II, POC plans to design, develop, and validate the MIGCOM system; conduct performance and qualification-type tests with and without preplanned failure modes to verify that the system developed in Phase I accurately identifies failure causes/modes; and evaluate and modify the design to address the results of testing.