FLIGHT TESTING
ACCELEROMETERS
Written By
Bob Metz
pcb.com | 1 800 828 8840
Flight
Testing
Accelerometers
While
computer
based
design
has
been
beneficial
to
aircraft
design,
findings
from
actual
flight
test
results
continue
to
be
critical
in
validating
those
computations.
This
has
translated
into
a
demand
for
more
accurate
accelerometers
in
rigorous
flight
test
installations.
The
highly
competitive
aircraft
market
requires
manufacturers
to
explore
new
designs
that
are
operationally
more
cost
effective,
as
in
those
that
use
composites
to
trim
weight,
while
pushing
the
performance
envelope.
This
means
that
aerospace
engineers
must
be
attuned
to
new
materials
and
structural
innovations,
as
well
as
characterizing
their
performance
limitations.
All
of
this
must
be
accomplished
without
compromising
safety
margins.
PCB
Piezotronics,
Inc.
(PCB)
has
introduced
Series
3741E,
which
is
a
new
line
of
MEMS-‐based
DC
response
accelerometers
that
demonstrate
the
attributes
needed
for
flight
test
applications.
The
company
offers
several
full-‐scale
ranges
from
±2g
to
±200g.
Featuring
high
sensitivities
of
2,000
mV/g
to
20
mV/g
respectively,
the
Series
3741E
differential
output
accelerometer
is
designed
to
make
precise
measurements
in
harsh
environments
and
provides
accurate
readings
while
being
subjected
to
severe
vibrations
over
a
wide
temperature
range.
Flight-‐testing
encompasses
a
number
of
different
installations,
each
with
its
own
unique
requirements
for
the
test
accelerometer.
Accelerometers
are
used
to
measure
rigid
body
motion
during
flight
load
cycling.
Flutter
testing
is
conducted
by
mounting
accelerometers
on
wing
tips.
Accelerometers
are
also
mounted
to
landing
gear
to
measure
shimmy
during
takeoff
and
landing.
For
all
applications,
the
accelerometer
must
provide
accurate
low
frequency
measurements
while
rejecting
high
frequency
noise
from
ancillary
vibration
sources.
Some
installations
require
the
accelerometer
to
be
exposed
to
water
spray,
mud
splash,
particle
impingement
icing,
and
temperature
extremes.
In
such
severe
applications,
an
alternative
titanium
housing,
hermetically
sealed
series
3711E
is
available.
The
sensing
element
of
the
3741E
features
a
proof-‐mass
and
attachment
system
that
are
bulk
micro
machined
from
the
same
single-‐crystal
silicon
wafer.
The
movement
of
the
proof-‐mass
is
directly
affected
by
acceleration
applied
in
the
axis
of
sensitivity.
The
sensing
element
is
connected
as
a
bridge
element
in
the
circuit,
with
differential
output
voltage.
Electrical
characteristics
of
one
portion
of
the
bridge
increase
in
value,
while
the
other
decreases
when
exposed
to
acceleration.
This
approach
minimizes
common
mode
noise
errors
and
improves
non-‐linearity.
A
proof-‐mass
is
laminated
between
two
wafers
using
a
glass
bond.
This
structure
provides
a
hermetic
enclosure
for
the
proof-‐mass
in
dry
inert
gas
environment,
providing
mechanical
isolation
and
protection.
The
sensing
element
itself
is
kept
small
through
the
use
of
cutting
edge
processes
such
as
deep
reactive
ion
etching.
Modifying
the
stiffness
of
the
proof-‐mass
suspension
system
attains
a
selection
of
full-‐scale
ranges
between
±2g
and
±200g.
A
high
natural
frequency
is
accomplished
through
the
combination
of
a
lightweight
proof-‐mass
and
suspension
stiffness.
Ruggedness
is
enhanced
through
the
use
of
mechanical
stops
on
the
two
outer
wafers
to
restrict
the
travel
of
the
proof-‐mass.
Gas
damping
mitigates
high
frequency
vibration
inputs
and
allows
the
sensor
to
measure
lower
vibration
levels.
This
damping
mitigates
the
accelerometer
output
from
saturation
which
can
occur
if
the
sensor
is
excited
by
random
vibration.
The
advantage
of
gas
over
liquid
damping
is
that
gas
is
minimally
affected
by
temperature
changes.
Series
3741E
contains
conditioning
circuitry
that
provides
a
high-‐sensitivity
output.
The
differential
signal
from
the
sensor
element
is
amplified
and
balanced
using
an
electrically
programmable,
integrated
circuit
(IC).
This
IC
also
provides
compensation
of
zero
bias
and
sensitivity
errors
over
temperature
using
a
continuous
correction
engine.
Power
to
the
accelerometer
is
in
the
form
of
a
simple
DC
voltage
from
+6
to
+30
VDC
with
less
than
10
mA
current
draw.
This
voltage
can
be
derived
from
laboratory
power
supplies,
automotive/marine
batteries
or
other
portable
power
sources.
Initially,
the
power
is
passed
through
a
voltage
regulator.
The
regulator
ensures
clean
power
to
the
microelectronics.
The
benefit
to
flight
testing
is
that
the
accelerometer
may
be
connected
directly
to
the
aircraft
DC
power
without
the
use
of
a
separate
signal
conditioner,
saving
cost
and
weight.
The
differential
output
from
the
new
accelerometer
allows
the
positive
output
signal
to
increases
with
acceleration
while
the
negative
line
proportionally
decreases.
The
output
lines
have
a
common
mode
voltage
of
2.5
VDC
above
circuit
ground.
The
result
is
a
minimum
accelerometer
threshold
resolution
of
0.1
milli-‐g’s
rms
for
the
±2g
rated
device
over
a
bandwidth
of
0
to
400Hz.
The
threshold
scales
proportionally
to
5.6
milli-‐g
for
the
±200g.
Upon
completion
of
the
accelerometer
assembly,
an
automated
calibration
step
is
conducted
at
discrete
temperatures
over
specified
temperature
range.
This
can
span
-‐55
to
+121
degree
Celsius.
The
IC
features
an
on-‐chip
temperature
sensor
for
accurate
thermal
corrections.
The
electronics
also
feature
low
pass
anti-‐alias
noise
filtering
and
reverse
polarity
protection.
Output
impedance
is
<120
ohms
maximum
and
the
accelerometer
output
stage
is
capable
of
driving
lines
in
the
hundreds
of
feet
along
the
aircraft
wings
or
tail,
back
inside
the
fuselage
to
the
flight
data
acquisition
system.
Series
3741E
is
packaged
in
a
hard
anodized
aluminum
housing
with
two
through
holes
for
secure
screw
mounting.
Two
screws
and
washers
are
provided
for
both
metric
and
SAE
mounting.
The
axis
of
sensitivity
is
perpendicular
to
the
mounting
plane.
The
marking
on
the
accelerometer
cover
faces
the
direction
of
positive
going
output.
The
low
profile
package
is
suitable
for
mounting
in
tight
spaces
or
three
accelerometers
can
be
attached
to
a
mounting
block
for
a
three
axis
arrangement.
An
optional
trixial
mounting
block
or
an
alternate,
the
Series
3713E
triaxial
single
ended
output
accelerometer
is
also
available
from
PCB.
Series
3741E, is
supplied
with
a
10
ft,
four
conductor
integral
cable
that
features
a
braided
shield.
This
cable
is
a
supple
enough
to
be
routed
around
tight
corners
and
the
shield
floats
on
the
transducer
end
so
that
a
singler point
connection
can
be
made
at
the
data
acquisition
end
to
avoid
current
loops
and
improve
EMI
protection.
The
cable
is
strain
relieved
at
the
sensor
from
the
housing
in
order
to
minimize
the
possibility
of
fatigue
failures
that
could
be
experienced
in
the
hundreds
of
hours
of
flight
testing.
PCB
Series
3741E
MEMS
based
DC
response
accelerometers,
with
their
small
size
and
ruggedness,
offer
multiple
advantages
in
flight
testing.
The
accelerometers
are
designed
with
the
necessary
durability
to
withstand
the
many
flight
test
cycles
required
of
an
accelerometer,
including
exposure
to
mechanical
and
thermal
extremes
over
long
durations.
Their
self-‐regulating
aircraft
power
supply,
amplified
output,
and
low
noise
makes
them
well
suited
for
flight
test.
PCB Piezotronics, Inc. is a designer and manufacturer of microphones, vibration, pressure, force,
torque, load, and strain sensors, as well as the pioneer of ICP® technology used by design engineers
and predictive maintenance professionals worldwide for test, measurement, monitoring, and control
requirements in automotive, aerospace, industrial, R&D, military, educational, commercial, OEM
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© 2019 PCB Piezotronics, Inc. In the interest of constant product improvement, specifications are subject to change without notice. PCB®, ICP®, Swiveler®, Modally Tuned®, and IMI® with associated logo are registered trademarks of PCB
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divisions of PCB Piezotronics, Inc.; Accumetrics, Inc. and The Modal Shop, Inc. are subsidiaries of PCB Piezotronics, Inc.
