Control Surface Buffet Load Measurement Navy SBIR FY2009.1 Sol No.: Navy SBIR FY2009.1 Topic No.: N091-013 Topic Title: Control Surface Buffet Load Measurement Proposal No.: N091-013-0758 Firm: MicroStrain, Inc. 459 Hurricane Lane Suite 102 Williston, Vermont 05495-3211 Contact: Steven Arms Phone: (802) 862-6629 Web Site: www.microstrain.com Abstract: Structural monitoring of Navy aircraft is of critical importance as the fleet ages. One critical area includes the control surfaces, which are subject to intense, dynamic buffet loading which can lead to structural cracking. The highly transient nature of buffet loading makes it difficult to measure using conventional sensors. We propose to solve this problem by combining a network of time-synchronized wireless load sensors with integrated microelectronics for static and dynamic loads sensing, data recording, communications, and energy harvesting. Our proposed sensors possess major advantages, including: sealed stainless packaging, full calibration prior to installation, rapid installation, and locations which enable a full computation of control surface forces and moments. Embedded firmware at each node will detect when buffet loads occur, and each wireless sensor node will automatically increase its sampling rate for high speed data recording. Data during normal aircraft maneuvers shall also be recorded, at a reduced sample rate. Time stamped, synchronized data will be stored in non-volatile memory and may be downloaded wirelessly at high rates upon receipt of a secure command. The embedded firmware also uses micro-power sleep modes whenever appropriate to enable powering by vibration energy harvesting, which will eliminate the need for battery maintenance. Benefits: Many applications for these wireless sensors will emerge as the prime manufacturers gain familiarity and confidence through our planned Phase I and II developments and working demonstrations. We anticipate that this will lead to significant commercialization opportunities as well as enhanced safety and reduced maintenance costs for the Navy's aircraft fleet. Poised for explosive growth, analysts have predicted annual revenues for wireless sensors to exceed $1B in 2009. However, there are still significant barriers to the widespread use of wireless sensors. These barriers include the need for calibration, integrated packaging, & frequent battery replacement. The development of a fully calibrated, micro-power, wireless structural loads sensor with energy harvesting capabilities will represent a major advance, and will open up many new applications in structural health monitoring and machine condition based maintenance. Return