Strain Sensors For Health Monitoring of High-Speed Rotating Equipment

Strain and stress tests for rotating parts are critical to the engine development cycle. However, there’s no reason to limit your data to test stands and scheduled spin tests. Long-term machinery health monitoring requires high-survivability strain sensors that can be deployed in the field and counted on to last throughout the life of the engine.

TurboTrack™: The First In-Situ Strain Monitoring System

Sensatek has designed and developed a revolutionary system of wireless, in-situ strain sensors to save you time and money while improving test and component life data. TurboTrack™ can even be deployed without continuous dismantling of high-speed rotating equipment. Roughly the size of a postage stamp, our ceramic-based polymer strain sensors are both compact in size and incredibly durable.

• Compact: The diminutive size makes it possible to install TurboTrack™ strain sensors directly on turbine blades and in hard-to-reach locations without a costly and time-consuming teardown of the engine.
• Durable: With over 40,000 hours of service life, you can trust the TurboTrack™ system to provide continuous machine condition monitoring and real-time data in the field. Maintain a full life model of engine health with accurate (and repeatable) measurement of strain, temperature, and transient torque events.
• Wireless: Routing wires throughout the engine for a sensor system with dozens of data channels is tedious, inefficient, and expensive. With TurboTrack™, it’s now possible to collect readings from numerous strain sensors under one access port. A single antenna is positioned through the slip ring, and the wireless sensor patches do the rest of the work.

Diverse Strain Sensor Applications

Our versatile temperature and strain sensors are in use across numerous industries and in many types of high-speed rotating equipment, including:

• Gas Turbines
• Steam Turbines
• Wind Turbines
• Hydro-electric
• Aviation & Aerospace
• Energy and Power Generation
• Oil and Gas
• Glass Making
• Petrochemical
• Industrial Automation
• Department of Defense, Air Force, and Other Military Branches

Engine health monitoring makes it possible to predict component failures before they happen, preventing costly outages, shutdowns, or potentially catastrophic damage. Maintain a clear view of the thermal performance of components like turbine blades, rotors, and gear shafts. Spikes or irregularities in thermal activity are strong indicators of torsion, strain, and wear and tear on these sensitive rotating parts — no matter the industry or application.

Why Trust TurboTrack™ Strain Sensors For Rotating Equipment?

Sensatek sensors have been carefully designed, tested, and verified in strain and stress tests for rotating parts in cooperation with many trusted organizations and OEMs. Research and development has been funded in part by the National Science Foundation, Department of Energy, and NASA. 

Industry-leading OEMs put the durability of TurboTrack™ to the test at the Siemens Casselberry Flame Rig, where they withstood 600+ shock cycles at 1,000 C/min and remained firmly bonded. While embedded on a SGT8000H rotor and a microturbine engine rotating wheel, our sensors handled 127,000 RMP at 810°C without fail. Further tests have shown the ability to survive environments up to 1,800°C for short periods.

Sensatek continues to receive accolades, awards, and grants for this cutting-edge temperature and strain monitoring system, including: 

• U.S. Department of Energy Office of Energy Efficiency and Renewable Energy Megawatt Ventures Competition Winner
• PowerGen Initiate! Winner 2019
• Florida Venture Forum Early Stage Business Pitch Winner
• Florida Aerospace Capital Forum 2018 Winner
• National Science Foundation I-Corps Program
• National Science Foundation STTR Phase 1 and SBIR Phase II Award
• Air Force STTR Phase I and STTR Phase II Award
• U.S. Department of Energy SBIR Phase 1 Award
• NASA STTR Phase I Award

Get in touch with Sensatek today for information on our pilot program and how the TurboTrack™ system of temperature and strain sensors can change the game for you. Engine testing and fleet monitoring have never been easier or more cost-effective.