Realization and Analysis of Mechanical Parts of the Multi-sensor Instrument for Aerodynamic Pressure Measurements

This paper presents the design of mechanical parts of a MEMS multi-sensor instrument for aerodynamic pressure measurement. Multi-channel pressure sensing instruments are essential for aerodynamic measurements. In many applications, such equipment is placed inside structural parts or objects, i.e., wind turbine blades, racing cars, UAVs, etc. The need for miniaturization, and requirements for high measurement performance and the number of measurement channels, represent significant challenges for further development of such devices for pressure measurement. The instrument consists of a signal processing unit and two multi-sensor modules. This paper is focused on the realization of both the instrument’s enclosure that houses the signal processing unit, and the multi-sensor module that contains previously developed MEMS multi-sensor silicon chips and the accompanying electrical circuitry, electrical and pneumatic connections. Traditional and additive manufacturing technologies were used in the manufacturing process. For multi-sensor modules, AISI 316 steel was used in the first case, and in the second two thermoplastic polymers (PLA and PETG). We have chosen an innovative approach in which the mechanical design takes into account the requirement for minimization of the deflection of the printed circuit board (PCB) inside the multi-sensor module due to the applied pressure. Finite element analysis (FEA) of the multi-sensor module was performed at a set pressure of 400 kPa in order to observe the deflection/warpage of the PCB and its influence on the electronic components on the PCB. Although our simplified analysis showed that the electronic board should be able to withstand the expected maximum pressure loads, some critical areas were found for which further investigation is recommended.