Robust and Versatile Speed Sensor for Turbochargers

Turbochargers are critical components of internal combustion (IC) engines on Unmanned Aerial Vehicles (UAVs). Control of the turbocharger speed is needed to avoid operation near resonant speeds and to optimize turbocharger performance and life. Currently, there are no robust flight sensors capable of measuring titanium blade turbocharger speeds at high temperatures with limited access. In this project, Creare is developing a turbocharger shaft speed sensor consisting of a robust, high temperature probe head and remote electronics. The sensor will work reliably with any blade material and will require minimal or no modification to the turbocharger hardware. In Phase I, we designed, built, and tested a prototype laboratory sensor. We used this sensor to measure the speed of multiple turbochargers and turbo-compressors. We demonstrated that our sensor can be easily integrated with multiple turbos, that it reliably and accurately measures shaft speed, and that it has more than sufficient frequency response for turbos operating at up to 250 krpm. In Phase II, we will build, test, and deliver compact and durable shaft speed sensors that are easy to install and meet all the performance and integration requirements of the Army.