In a research study preventing tail-rotor bearing failure - a catastrophic failure - the customer needed to be able to measure the oil level in the rotor hub oil reservoir.
With a maximum rotation speed of 800rpm, any solution had to withstand high levels of vibration.
Initially for a test rig, the sensor had to fit an existing aperture in the rotor hub, minimise weight, include locking wire positions and an integrated connector. A minimal power consumption of typically 10mA @12 volts for a battery or energy harvesting power source; a fully sealed, inverted operation design to ensure no oil leakage through the sensor resulting from high centrifugal forces.
Incorporating a threaded interface to suit an AN814-6 mounting with 1.65mm and 1.9mm diameter locking wire positions, the metallic parts of the sensor were wholly manufactured from Titanium to minimise weight. Fully sealed to a minimum pressure rating of 0.3 bar, an aerospace approved connector was integrated into the housing. The minimal power requirements were also achieved.
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