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Wind tunnel testing is a foundational method in aerodynamic research and development, critical for validating the performance and safety of aerospace and defense systems. The acquisition of precise force and pressure data is the primary objective of these tests. SOUSHINE develops and manufactures advanced force sensing solutions that provide engineers and researchers with the high-fidelity data required to analyze aerodynamic performance, optimize designs, and validate computational fluid dynamics (CFD) models.
What is Force Sensing in Wind Tunnel Testing?
In the context of wind tunnel testing, force sensing is the systematic measurement of aerodynamic forces and moments exerted by airflow on a test object (often a scaled model of an aircraft, vehicle, or component). The primary goal is to quantify how the object behaves in a controlled aerodynamic environment. Key measurements include:
- Lift: The force component perpendicular to the direction of airflow.
- Drag: The force component parallel to and opposing the direction of airflow.
- Surface Pressure Distribution: The variation of pressure across the surfaces of the model, which is fundamental to understanding how lift and drag are generated.
- Moments: The rotational forces (pitch, roll, yaw) acting on the model’s center of gravity.
Accurate measurement of these parameters is essential for determining stability, control, and overall aerodynamic efficiency.
How SOUSHINE Force Sensors are Implemented in Aerodynamic Analysis
Traditional wind tunnel measurement relies on external balances or a limited number of discrete pressure taps. SOUSHINE’s Force Sensing Resistor (FSR) technology offers a modern, integrated approach for acquiring more comprehensive data directly from the model’s surface.
The implementation process involves three key stages:
- Sensor Integration: Our thin, flexible FSR arrays are applied directly to the surface of the wind tunnel model, such as an airfoil, wing, or fuselage section. Due to their low profile (often less than 0.5mm), they do not significantly alter the model’s geometry or disrupt the boundary layer airflow, ensuring data integrity.
- Data Acquisition: As air flows over the model, the resulting pressure variations exert force on the FSR sensors. The sensors respond with a corresponding change in electrical resistance. This analog signal is captured by a data acquisition system (DAQ) and converted into quantitative force or pressure values.
- Data Processing & Visualization: The collected data from the sensor array is processed to generate high-resolution pressure maps of the model’s surface. This detailed mapping allows for precise identification of high- and low-pressure zones, shockwave locations, and areas of flow separation. The integrated data can also be used to calculate total lift and drag coefficients.
Why Use SOUSHINE Force Sensing Technology for Wind Tunnel Testing?
Integrating SOUSHINE’s FSR technology into your wind tunnel testing protocols provides distinct technical advantages that lead to more accurate and comprehensive results.
- High Spatial Resolution: FSR arrays can be configured with a high density of sensing points, enabling detailed surface pressure mapping that is impractical with conventional pressure taps. This provides a more complete picture of the aerodynamic forces at play.
- Conformal and Non-Intrusive: The thin and flexible nature of our sensors allows them to conform perfectly to complex aerodynamic surfaces without creating protrusions that would otherwise trip the airflow and corrupt the data.
- Durability in Test Environments: Manufactured with robust materials, our sensors are designed to withstand the operational stresses, vibrations, and temperature fluctuations characteristic of wind tunnel testing environments.
- Customization for Specific Models: We collaborate with clients to design and produce custom sensor shapes, sizes, and array layouts tailored to the unique geometry of their specific test articles, from small components to complete aircraft models.
- Efficient Data Collection: An integrated FSR array can replace hundreds of individual pressure taps and their associated complex tubing, simplifying model preparation, reducing setup time, and minimizing potential points of failure.
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FAQ
How do SOUSHINE’s FSR sensors compare to traditional strain gauges or balance systems?
Strain gauges and balance systems are excellent for measuring total, integrated forces and moments on the entire model. Our FSR arrays excel at providing distributed surface pressure data. The two systems are complementary; FSRs explain why the total forces are what they are by showing the detailed pressure distribution, while balances measure the net result.
Can your sensors operate in transonic or supersonic wind tunnels?
Our sensors are designed to operate across a wide range of conditions. However, performance in specific high-speed or high-temperature environments should be discussed with our engineering team. We can select materials and designs to meet the specific requirements of your test envelope.
What is the process for integrating your sensors onto our custom wind tunnel model?
The process begins with a consultation to understand your model’s geometry and testing goals. We then design a custom sensor array. The thin, adhesive-backed sensors are then carefully applied to the model’s surface. We provide detailed application guidelines to ensure optimal bonding and performance.
What data output is provided by the sensor system?
The raw output is a change in electrical resistance. When used with a calibrated data acquisition system, this is converted into force (Newtons) or pressure (Pascals) values for each sensing point in the array. This data can be exported in standard formats for analysis in software like MATLAB, LabVIEW, or Python.
Are the sensors reusable?
The sensors are designed for robust performance throughout a test campaign. However, since they are typically bonded to a specific model with strong adhesive to ensure they do not detach during testing, they are generally considered part of that model for its testing lifecycle and are not easily transferred between different models.