WaLruS - wireless strain-gauge digital acquisition radio system

WWaLruS -
wired strain-gauge digital acquisition system

WaLruS picture WWaLruS picture

Download bibliography: Abstract submitted to
12th International Conference on Experimental Mechanics - ICEM12 Bari, August 2004 (.pdf)



Strain and vibration can be commonly measured using strain-gauge sensors. The strain-gauge is a strain dependent resistor whose value has very little displacements from the nominal value. The displacement can be some percentage of the nominal value, few Ohm from a typical value of 120 Ohm. Due to the electronic noise the resistor value measurement is very difficult. Usually the strain-gauge is installed in one or two Wheatstone bridge branches. The bridge unbalance is amplified by a differential amplifier. The sensor is glued on the part under test, often in a difficult access situation. Whenever this happens the strain-gauge is connected to the front-end electronics by cables long enough resulting in one or more of the following troubles:
· the connection cables ohmic resistance can cause a voltage drop. This results in a wrong bridge drive and consequently in a wrong measurement because the sensitivity depends from such bridge voltage drive. When possible the problem can be avoided reducing the connection length or using a Kelvin probe;
· the connection cables can be microfonic enough to worsen the measurement. Also in this case cutting the cables length reduce the problem.
· the strain-gauges are low value resistors so the relevant measurement is very sensitive to the surrounding electro-magnetic fields. Every electro-magnetic source as an electric motor or a power inverter must be kept as far away as possible. Often the measurement cannot be performed far away from some of these noisy sources.

Many times the troubles explained above are avoidable performing a good choice in the cable quality and in the way the sensor is cabled. In other situations the sensor cabling is impossible, for example measuring the strain and the vibration of a rotating shaft. The WaLruS and the WWaLruS are electronic equipments for solving all the cabling troubles in the strain-gauge data acquisition. The WaLruS and the WWaLruS are very compact electronic equipments so they can be installed very close to the sensor bridges. Using the WaLruS and the WWaLruS the physical connection between the sensor and the front-end electronics can be reduced to millimetric length. Moreover the WaLruS and the WWaLruS outputs are just digital data, ready for a direct acquisition via a common Personal Computer serial port. The resolution of the output data is 10 bits, the output data rate is 1 kHz data rate for the WaLruS and 2 kHz for the WWaLruS. The WaLruS is connected to the PC via a radio-link, overcoming every situation of impossible cable connection. The rotating shaft is one example. The WWaLruS is even smaller than the WaLruS and it's connected to the PC via a four wires cable.. The WWaLruS output data travel through the cable just in digital format. This results in excellent noise immunity. So the WWaLruS is the best choice whenever the measurement must be performed in very noisy environmental conditions or very far away from the PC. Because of its small dimensions the WWaLruS is suitable in every narrow space situation. Both WaLruS and WWaLruS perform an high performance a high quality digital acquisition of strain gauge at very low price.

The WaLruS system

The following figure illustrates the WaLruS system.


As depicted in the figure above, the WaLruS transmitter circuit hosts an analog front-end, an auto balancing circuit and a Wheatstone bridge. The transmitter physical dimensions are very small. The printed circuit board of WaLruS transmitter encloses a small loop antenna. Optionally the user can replace the loop with a short wire. In this way the WaLruS become smaller. The overall transmitter dimensions are about 24.13 X 34.54 mm, removing the loop antenna it becomes about 24.13 X 23.75 mm (see fig.).

Unlike the analog systems the TX transmits just a digital data stream. The sensor signal is amplified (on request to 5000X) and sampled at 1 kHz rate (10 bits resolution). The extremely small path between the transducer and the front-end electronics results in a very low electromagnetic environmental noise. The WaLruS receiver (RX) is designed using a very new circuit solution. It encloses all the radio-frequency section (FSK receiver), the local oscillator that is a DDS type followed by a PLL up-converter. The RX uses a micro controller for the tuning and for the RSSI acquisition. The output of the receiver, for the PC data connection, is a serial RS-232C standard port for the PC data connection. The data stream coming from the RX can be displayed on the PC screen and recorded in a file for further elaborations. The software is enclosed with the equipment.

The WWaLruS system

The following figure illustrates the WiredWaLruS system.

Also for the WWaLruS the front-end circuit is complete of Wheatstone bridge with analog circuit, auto balancing system and analog to digital converterThe WWaLruS front-end circuit consist of a Wheatstone bridge, a precision instrumentation amplifier an auto balancing system and an analog to digital converter. The WWaLruS physical dimensions are even smaller then the WaLruS TX because of the aerial lack. The circuit is powered directly by the four wires connection cable and is about 15.24 X 22.23 mm (see fig.).
Unlike the analog systems the WWaLruS also transmits just a digital data stream. The sensor signal is amplified (on request up to 5000X) and sampled at 2 kHz rate (10 bits resolution). The extremely small path between the transducer and the front-end electronics results in a very low electromagnetic environmental noise. The WWaLruS PC interface card hosts the power supply and the RS232C standard interface. The front-end power supply can be remotely switched on or off via software. The digital data travels on the wire in balanced mode resulting in a long path capability and low noise emission. The front panel dimensions of the PC interface cards are close to a standard DB9 connector. In this way the User can directly plug it in the standard serial port connectors behind the all PC's. The data stream coming from the RX can be displayed on the PC screen and recorded in a file for further elaborations. The software is enclosed with the equipment.


 

Technical specifications:

WaLruS_TX:

  • Gain range: 1 to 5000 on request
  • Analog bandwidth: DC to 500 Hz
  • Bridge auto balancing: automatic at power-on
  • Sampling frequency: 1kHz
  • Resolution: 10bit
  • TX operating frequency: 380 MHz to 450 MHz (433.6 MHz standard)
  • Output TX power: on request -10 dBm to +6 dBm
  • Range: 0.5 m to 20 m depending upon conditions
  • Power supply: 3.2V to 3.6V battery
  • Battery autonomy: 3 to 9 hours depending upon strain-gauge and output power
  • Dimensions: 24.13 X 34.54 mm with aerial 24.13 X 23.75 mm without aerial

WaLruS_RX:

  • Supply: 220 VAC, 8-15 VDC
  • Frequency: 430 MHz - 440 MHz 100 Hz step
  • Outputs: analog datum, digital datum, threshold level, RS232C, optionally IFa
  • IF: 10.7 MHz single conversion
  • Dimensions: 120 X 85 X 32 mm

WWalruS_Frontend:

  • Gain range: 1 to 5000 on request
  • Analog bandwidth: DC to 1000 Hz
  • Bridge auto balancing: power-on or via software
  • Sampling frequency: 2kHz
  • Resolution: 10bit
  • Max cable length: 50m more on request
  • Dimensions: 15.24 X 22.23 mm

WaLruS_Interface:

  • Power supply: 8-15 VDC
  • Output: RS232C null-modem
  • Dimensions: 80 X 32 X 12 mm

Customisation capability:

WaLruS and WWaLruS systems can be used with much other kind of transducers. On request AGE Scientific can customize WaLruS and WWaLruS for other applications or sensors.