A Novel Hybrid-Mode Curved-shape SAW (CsSAW) Sensor For The In-Situ/Real-Time Torque And Temperature Measurement of Rotor Shaft in Harsh Environments

燃气涡轮发动机转子转矩是反映发动机结构健康状态、动力效率和系统动态性能的关键参数，但高温环境给转矩监测带来极大挑战，现有的转矩传感器大多无法正常工作。在本提案中，我们将研究一种可以在高温（900℃）燃气轮机发动机环境下工作的新型扭矩传感器。本项目将涉及传感器的结构、传感器材料、传感机理和实验测试等一系列基础研究课题。一旦开发成功，该传感器将能够更好地控制燃气涡轮发动机，从而提高能源效率和安全系数。除了对燃气涡轮发动机行业的影响外，该传感器还将对汽车内燃机的功率效率、燃煤电厂和核电站的传感和控制、喷气发动机的监测、航空航天推进系统、高超音速飞行器发动机和天然气钻井监测产生重大影响。此外，该项目将通过新课程的开发，以及对研究生，本科生和K-12学生的研究指导，使大学受益匪浅。它还将为未被充分代表的少数民族和女学生提供机会。本研究的目的是实现燃气涡轮发动机转子转矩的实时测量，以提高发动机的动力效率和系统动态性能。为了实现这一目标，本提案的目标是开发一种新型弯曲表面声波（CsSAW）传感器，用于在恶劣环境（900℃）下对转子轴进行原位/实时扭矩和温度测量。该传感系统监测转子轴在恶劣环境下的动态扭矩和局部温度，评估其运动性能，并通过检测异常扭矩分布来预防早期故障。研究将通过以下途径进行：(1)对表面声波沿曲面传播的基础研究和研究；(2)新型扭矩/温度传感机构的研究；(3)高温燃气轮机模型环境的实验测试。该项目的成功完成将产生一种新型传感器，它将在发动机工业、柔性电子、航空工业、柔性电子和天然气钻井工业中得到广泛应用。大学和世界领先的发电行业在不同研究领域的互动将指导基础研究，以解决这一关键的行业需求，并加速实施已开发的知识，以产生直接的行业影响。该奖项反映了美国国家科学基金会的法定使命，并通过使用基金会的知识价值和更广泛的影响审查标准进行评估，被认为值得支持。

The torque of gas turbine engine rotors is a critical parameter that reflects the structural health status, powering efficiency, and system dynamic performance of the engine, however, the high temperature environment makes the torque monitoring extremely challenging and most existing torque sensors will not operate normally. In this proposal, we will investigate a new type of torque sensor that could operate in high temperature (900o C) gas turbine engine environment. A series of fundamental research topics will be addressed in this project such as the configuration of the sensor, sensor materials, sensing mechanism and experiment test. Once developed successfully, the sensor will enable a better control of the gas turbine engine resulting in higher energy efficiency and better safety factor. In addition to the impact to gas turbine engine industry, the sensor will also have significant impacts on the power efficiency of vehicle internal combustion engines, sensing and control of coal-fired and nuclear power plants, monitoring of jet engines, aerospace propulsion systems, hypersonic vehicle engines and gas drilling monitoring. Furthermore, this project will substantially benefit the university through new course development, as well as research mentoring for graduates, undergraduates, and K–12 students. It also will provide opportunities to underrepresented minorities and women students.The goal of this research is to achieve real time measurements of rotor torque of gas turbine engine to improve the engine power efficiency and system dynamic performance. As a step towards this goal, the objective of this proposal is to develop a novel Curved-shape Surface Acoustic Wave (CsSAW) sensor for the in-situ/real-time torque and temperature measurement of rotor shaft in harsh environments (900o C). This sensing system monitors the dynamic torque and local temperature of the rotor shaft in a harsh environment, evaluate the kinematic performance, and prevent earlier failure by detecting abnormal torque distribution. The research will be conducted through the following approaches: (1) Fundamental study and research on the surface acoustic wave propagating along curved surface; and (2) Investigation of a novel torque/temperature sensing mechanism, and (3) Experimental test in a mock-up high-temperature gas turbine engine environment. The successful completion of this project will generate a new type of sensor that will find numerous applications in engine industry, flexible electronics, aviation industry, flexible electronics, and gas drilling industry. The interaction of the universities and the world’s leading power-generation industry at different ends of the research spectra will guide the fundamental research to solve this critical industry need and enable accelerated implementation of the developed knowledge to generate immediate industry impacts.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.