Intelligent Sensor System for Rocket Propulsion Testing

Physical Sciences Inc. (PSI) and Auburn University propose to complete development of a Smart Sensor Module (SSM) to enable wireless sensing capabilities in rocket propulsion systems. The SSM is an electronics interface designed to connect to trusted, flight-qualified, and commercially available sensors without altering the measurement technique. At each sensor location, the SSM serves as a node in a wireless mesh network, allowing each node to transmit and receive data while providing onboard computing for real time decision making. The SSM increases NASAs capabilities by eliminating labor-intensive tasks such as routing and securing cables, and will improve sensor accessibility in locations that are difficult to diagnose. In Phase I, PSI created a workhorse SSM capable of wireless communication in a mesh network, while Auburns aggregation methods were used to integrate the PSI sensor network with a user friendly software interface. Multiple SSMs were built and demonstrated in a single wireless network, simultaneously transmitting pressure and temperature data to the gateway with synchronized time stamps. In Phase II, the SSM hardware design will be advanced to the final SSM product size and weight, and the integrated network will be demonstrated on one of PSIs rocket engine test stands. This program will result in a final product at the conclusion of the Phase II program, offering a low risk, near-term transition to NASA and commercial propulsion facilities. Physical Sciences Inc. (PSI) and Auburn University have developed an integrated sensor system for rocket propulsion testing using a wireless mesh network of smart sensors. This sensor system is designed for implementation on both ground-based test stands and flight systems, and accommodates the diverse environmental, response time, and accuracy requirements of rocket engines. This system offers advanced capabilities by combining PSI’s Smart Sensor Module with Auburn University’s gateway interface software, and connects directly to the existing, proven sensors conventionally used on propulsion test stands. This is the first integration of modern system-on-a-chip (SoC) capabilities in a wireless sensor module for propulsion applications. By pairing the Smart Sensor Module with a user-friendly data aggregation software, this STTR program has enabled rapid reconfiguration and expansion of sensor suites at NASA’s rocket propulsion test stands in a way that is not feasible in a wired system. The transition of the Phase I workhorse SSM to a final SSM product design is a key requirement in Phase II. The Phase II program has five technical objectives. First, PSI will build the final SSM design in an explosion proof housing with a configurable design for operation with strain gauges, load cells, 4-wire pressure transducers, 3-wire pressure transducers, 2-wire pressure transducers, thermocouples, RTDs, thermistors, and miscellaneous analog voltage devices. Second, automatic network adaptation will be demonstrated upon addition/removal of a Smart Sensor Module, including automatic clock synchronization with an IRIG timing system. Third, automatic operation of the gateway software platform will be demonstrated with aggregation, display, forwarding, and integration of data using an open-source code. Fourth, the SSM will automatically perform a sensor self-health check, including shunt calibration, input/output bridge resistance measurement, zero offset measurement, and measurement of remaining battery life. Fifth, PSI will validate full operation of multiple SSMs in a wireless network during an rocket engine firing in Test Cell 1B at PSI’s propulsion and energetics facility in Epping, NH. The Phase II program will conclude with the delivery of the final product to NASA.

Successful demonstration of a smart, wireless sensor network will have significant applicability to ground testing and flight missions for NASA. Reductions in labor assigned to the design, assembly, and implementation of sensor systems will lead to significant cost savings. Using SSM’s with sensors that have flight heritage reduces the risk of installing the network in existing systems. Wireless sensors allow for diagnostics in previously inaccessible locations and smart sensors enable decentralized decision-making, making NASA systems safer. The commercial space industry and DoD can use the expanded diagnostics and cost savings offered by intelligent sensor networks in their own propulsion systems. Power and energy industries have similar needs for real-time networks of sensors capable of high-acquisition rates. The proposed technology can be used in aircraft or oil and gas systems that require data from difficult to access areas.

This is early/mid-stage (TRL 5) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

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