Non-contact Torque and Load Monitoring Using Magnetic Stress Gage Networks

This proposed Phase II SBIR will raise the Quadri-Directional Magnetic Stress (QD-MSG) noncontact torque sensor technology to a level suitable for flight testing. In Phase I, a series of static and dynamic tests were carried out that demonstrated the QD-MSG’s capability to (1) provide torque measurement in a dynamic test environment representative of an Army rotorcraft; (2) independently measure torque, bending and axial loads; (3) correct for hysteresis in the magnetic permeability vs. stress relationship; (4) correct for temperature effects; and (5) correct for variations in sensor proximity to the rotating shaft. In Phase II, we will continue refining and enhancing the data processing and calibration methods with the goal of achieving a highly reliable measure of rotor shaft torque, free of contamination from unwanted parasitic effects, instrumentation or material drift, robustly calibrated and stable for the duration between maintenance events, and suitable for real-time rotorcraft flight control. We will upgrade the static and limited dynamic test facilities at JENTEK and perform additional OEM-supported full-scale tests targeting specific Army rotorcraft configurations. The Phase II will also include planning for transition of electronics and cabling configurations for on-board implementations to support flight testing and transition to the fleet.