Short Distance Telemetry for Piston Monitoring. Design and Development of Short Distance Telemetry for Engine Condition Monitoring.

Abstract

Piston telemetry research involves monitoring the temperatures at specific internal location points within a combustion engine piston. The temperatures are detected with type K thermocouples as voltages and processed to convert them into temperatures using cold junction compensation methods. The present system uses a specific sensor designed to operate in the high temperature environment within the piston, reading multiple thermocouples. Because of the reciprocating motion of the piston, power generation is intermittent and available only when the piston reaches near bottom dead centre, using inductive coupling to power the sensors and transmit data to an evaluation unit for data processing. The planned system involves designing and building a prototype telemetry unit using ¿off the shelf¿ components that integrate the reading of thermocouple outputs, signal processing and cold junction compensation. Wireless telemetry is adopted for data transmission with an integrated Bluetooth and microcontroller module. The data acquisition module can be adapted for other sensors by adapting the firmware uploaded to the microcontroller. The hardware electronics are envisaged to be encased in thermal insulation to enable operation in high temperature environments. The considered system requires a power supply for the integrated components in the form of a power generator and that it should meet two criteria: to be located within confined spaces and to be permanently available, without having to dismantle systems to change batteries. The selected method is an induction generator constructed from a coil stator connected to the piston connection rod big end and a permanent magnet rotor connected to the crankshaft. The suggested mechatronic system is validated against the present system by comparing both systems to determine whether wireless telemetry can perform within acceptable tolerances and limits for the specified task. Then, for acceptable performances, reduce costs and include flexibility to operate in multiple environments. Bench testing shows that the power generator is capable of driving the sensors and the Bluetooth integrated DAQ system.