Automated Data Acquisition for a Prognostics and 

Diagnostics Health Monitoring System 

by Gregory Mitchell, Marvin Conn, Russell Harris, and Andrew Bayba 

ARL-TR-4523 July 2008 

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Army Research Laboratory 

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ARL-TR-4523 July 2008 

Automated Data Acquisition for a Prognostics and 

Diagnostics Health Monitoring System 

Gregory Mitchell, Marvin Conn, Russell Harris, and Andrew Bayba 

Sensors and Electron Devices Directorate, ARL 

Approved for public release; distribution unlimited. 
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Automated Data Acquisition for a Prognostics and Diagnostics Health 

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Gregory Mitchell, Marvin Conn, Russell Harris, and Andrew Bayba 

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14. ABSTRACT 

The military has mandated the need for continuous health monitoring to be implemented for Prognostics and Diagnostics (PD) 

applications at the mechanical and electronic level of fielded systems. The variety of military systems dictates the need for a 

highly flexible design that can be easily modified for different applications. Data acquisition is a core component of the PD 

process to get valuable information from the monitored system to a processing module for the execution of PD algorithms. 

This report addresses the design architecture of a PD Sensor Module (PDSM) for a Prognostics and Diagnostics Health 

Monitoring System (PDHMS) that can be introduced for electronics PD in a wide range of military systems. The use of this 

PDSM prototype in provoked electronic fault testing (PEFT) on a specific military platform will also be discussed. 

15. SUBJECT TERMS

Prognostics and diagnostics, wireless health monitoring system, data acquisition, provoked fault testing 

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Gregory Mitchell 

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iii 

Contents 

List of Figures iv

Acknowledgments v

1. Introduction 1

2. The CROWS Platform 1

2.1 System Functionality.......................................................................................................2 

2.2 Provoked Electronic Fault Testing..................................................................................2 

3. The Prognostics and Diagnostics Sensor Module (PDSM) 4

3.1 PDSM Design..................................................................................................................5 

3.2 Wireless Communications...............................................................................................6 

4. Provoked Electronic Fault Data 6

5. Conclusion 8

6. References 9 

Distribution List 10 
iv 

List of Figures 

Figure 1. CROWS platform highlighting the four elements controlled by the drives...................2 

Figure 2. CROWS drive control circuit card. Each drive has an identical card with a fuse.........3 

Figure 3. Operational laboratory data collection system implemented on the CROWS test 

bed..............................................................................................................................................3 

Figure 4. Overall design concept for a full PDHMS. .....................................................................4 

Figure 5. PDSM block diagram. .....................................................................................................5 

Figure 6. Current data acquired for a faulty fuse on the elevation control circuit card.................7 

Figure 7. Ambient temperature data for a faulty fuse and surrounding circuitry on the 

elevation control circuit card. ....................................................................................................7 
v 

Acknowledgments 

We would like to thank Kwok Tom and Derwin Washington of ARL for their efforts in 

collecting the sensor data discussed in this report. We would like to thank George Garcia and 

Michael Lospinuso from Picatiny Arsenal for allowing us access to the CROWS test bed. We 

also thank Scott Schmidt, engineering student at Drexel University for his contributions on the 

design of the PDHMS. 
vi 

INTENTIONALLY LEFT BLANK. 
1 

1. Introduction 

The growing complexity of military platforms creates a need for the integration of Prognostics 

and Diagnostics Health Monitoring Systems (PDHMS). PDHMS acquire, store, and 

communicate data gathered from sensors that monitor essential platform components to 

determine its current diagnostic status, and use this diagnostic data to make reliable 

prognostications of remaining operational life expectancy based on a platform usage profile. The 

need to monitor legacy platforms that do not have integrated prognostics and diagnostics (PD) 

capability means the PDHMS architecture must be flexible enough to meet varying data 

acquisition, communication, processing, and storage requirements. 

Benefits of integrating an automated PDHMS include continuous user awareness of platform 

operational status and a reduction of maintenance costs by facilitating condition based 

maintenance as opposed to a fixed time based maintenance schedule. Automating the PDHMS 

mean that diagnostics sensors can run continuously and discretely with functionality remaining 

transparent to the user. This data transfers to a remote PC, laptop, or handheld device acting as 

the Prognostics and Diagnostics Control Station (PDCS). 

This report discusses implementation details of a highly flexible automated PD sensor module 

(PDSM) prototype presently under development at the U.S. Army Research Laboratory (ARL) to 

be incorporated for data acquisition in a PDHMS. The ARL PDSMP has the capabilities to 

monitor fielded electronic systems and perform data acquisition functions on key test points of 

both legacy platforms and new platforms for PD analysis. These test points include system 

ambient temperatures, component surface temperatures, component voltage and current levels, 

and system vibration and shock behavior. The PDSM also keeps historical records of when 

measured parameters cross known thresholds that can lead to system failures. Threshold and 

usage data can be used strictly as a precursor or also to develop more sophisticated prognostics 

algorithms for the platform in question. 

2. The CROWS Platform 

Though the flexible design of the ARL PDSM can be implemented in a variety of electronic 

systems, we are using the Common Remotely Operated Weapons Station (CROWS) as the initial 

test platform. CROWS is a gunner-operated system capable of remotely aiming and firing a 

suite of crew-served weapons from inside the relative safety of a vehicle (1). 
2 

2.1 System Functionality 

CROWS integrates four separate drives individually controlled by four identical circuit cards. 

These drives control the sensor unit, actuator, 360 degree azimuth rotational pivot, and 80 degree 

vertical elevation control unit, which are indicated in figure 1. 

Figure 1. CROWS platform highlighting the four elements controlled 

by the drives. 

The actuator engages the weapon’s cocking mechanism and activates the trigger. The sensor 

unit incorporates a live video camera for daytime use and a thermal imaging camera for use in 

darkness. Both cameras use a laser range finder, which allows the gunner to zoom on targets, 

lock onto them, and maintain that lock accurately while the vehicle is in motion. The camera 

and the weapon can be used together or separately, allowing the gunner to look one way with the 

weapon pointed another. 

The gun itself is controlled by a joystick which gives the gunner 100-percent functionality, 

allowing the operator to control the weapon with just one hand. The weapon can be aimed up to 

60 degrees above and 20 degrees below horizontal and can turn a full 360 degrees in azimuth (1). 

2.2 Provoked Electronic Fault Testing 

Provoked electronic fault testing (PEFT) is defined as intentionally overloading the electronics in 

the system to provoke a fault. For the CROWS system, PEFT is used to characterize indicators 

preceding a fuse trip, and fuse degradation caused by multiple trips. The fuse trips as a result of 

a temperature increase caused by an increased power draw in the control circuit. An example of 

a drive control circuit and fuse is shown in figure 2. 

Currently, the prototype PDSM is being developed to monitor fuse temperatures, component 

surface temperatures, component voltage and current levels, and system vibration and shock 

behavior. The temperature, current, and voltage sensors will continuously monitor the fuses and 

surrounding circuitry to collect data on system behavior leading up to the provoked electronic 

fault. This data will be used to develop monitoring techniques and algorithms to detect and 

prevent possible fuse failure in other military systems. 
3 

Figure 2. CROWS drive control circuit card. Each drive has an 

identical card with a fuse. 

Figure 3. Operational laboratory data collection system implemented 

on the CROWS test bed. 

Presently, to obtain data from the CROWS system the drives must be dismantled and sensors are 

manually attached to the circuit cards in a laboratory. An example of an active data collection 

setup is illustrated in figure 3. While this setup successfully collects the data needed to develop 

PD analysis on the CROWS test bed in the laboratory, to perform PD on a fielded system the 

data acquisition must be unobtrusive and transparent to the system operator. The ARL PDSM 

will be exclusively internal, and use the wireless IEEE 802.15.4 protocol to transfer data to the 

PDCS within the vehicle cabin. This eliminates the need for any external circuitry, and the need 

for the operator to manually extract data from the system. 
4 

3. The Prognostics and Diagnostics Sensor Module (PDSM) 

Figure 4 shows the overall system design concept of the full PDHMS. The PDHMS is composed 

of one or more PDSMs designed to independently take measurements on test points of interest 

and the PDCS. The PDSM is programmed through the use of the standard JTAG interface, and 

can be programmed to have its wireless IEEE 802.15.4 hardware enabled or disabled depending 

on the application. 

The PDSM is designed to store the data acquired from the test points until the data can be 

transferred to the PDCS. A PDCS running the wireless protocol can remotely request and 

retrieve all acquired data from the PDSM, and perform a more extensive data analysis. 

A flexible design means any number of PDSMs can be incorporated into a PDHMS to monitor a 

system of interest. They can communicate with the PDCS either via wireless communications, 

or through the I2C hardwired serial interface. 

The PDSM is fabricated on a custom printed circuit board (PCB) using commercial off the shelf 

components. The heart of the design is the use of the Texas Instruments low power MSP430 

microcontroller (MCU) and the CC2420 ZIGBEE low power transceiver. The PCB dimensions 

are 2 inches by 4 inches. The MSP430 can operate from either a 6 megahertz (MHz) clock or a 

slower 32 kilohertz (KHz) clock. Because measurements will be made from multiple sensors, 

and the aggregate data rates are anticipated to be higher than can be supported by the 32 KHz 

clock, the 6 MHz clock will be required. 

Figure 4. Overall design concept for a full PDHMS. 
5 

3.1 PDSM Design

Figure 5 shows a block diagram showing the general layout of the PDSM design. The general 

functionality of the PDSM is to measure system current draws, surface temperatures voltages of 

interest, and shock and vibration behavior of various test points. Due to the low voltage MCU, 

all sensors have circuit protection hardware inline with the sensor test pins to minimize the 

possibility of damage to the micro-controller. 

Figure 5. PDSM block diagram. 

The PDSM is designed to be easily integrated into a variety of applications. The card is powered 

by +5 volts and +28 volts provided by the test platform itself. When the PDSM is placed within 

system casing the wireless capability can be disabled to prevent interference system 

functionality. When the wireless communications capability is disabled, an I2C interface allows 

data transmission via serial communications across two serial wires. 

To measure current draw, a CSA-1V-SO surface mount Hall Effect current sensor is used. This 

is done by placing the CSA-1V-SO chip assembled on a PCB near the test point of interest and 

relaying measurements to the PDSM through one of the MCU sensor connections. 

Surface temperatures are measured using K-type thermocouples because of their general 

flexibility. There are three MCU connections for connecting thermocouple sensors for 

temperature measurements. Standard signal conditioning and establishing an isothermal block is 

required in the design for these thermocouple inputs so that analog-to-digital converters (ADCs) 

can make the proper measurements. 

Shock data is measured using a Vibra Metrics Model 3000 Miniature Tri-Axial Accelerometer 

capable of measuring ±500G’s. Proper signal conditioning is provided from the sensor board to 

interface to the accelerometer. In addition to supporting accelerometer measurements, an 

inexpensive ST LIS302DL SPI/I2C interface 3-axis accelerometer capable of making 

measurements at a maximum of ±8g’s and 400 Hz is integrated onto the PCB. 
6 

To support PDSM data storage, the design incorporates multimedia memory storage cards 

capable of storing gigabytes of data. The PDSM has two Multimedia Card/ Secure Digital 

(MMC/SD) slots. One is used for data storage, and the other is a spare that allows for an 

additional insertion point of one of the many commercially available products such as IEEE 

802.11, Bluetooth, Modem’s, or GPS devices to name a few. 

Key to the performance of the PDHMS is the design of a flexible software architecture that will 

provide PDSM, and will interface to the PDCS. Software development will be implemented 

through the use of the IAR Embedded Workbench software development package for 

programming the MSP430 architecture, and C++ for control on the workstation. 

3.2 Wireless Communications 

The PDSM includes the ability to enable wireless communications for transferring acquired data. 

This feature enables the PDSM to operate within systems that may have wiring or weight 

restrictions related to the addition of cables for communication purposes. Since the PDSM will 

have to operate in a variety of environments, the 2.4 gigahertz (GHz) international Industrial, 

Scientific, and Medical (ISM) band is used. 

IEEE 802.15.4 is the standard used to implement wireless communications in the PDSM. This 

addresses the needs of low-rate wireless personal area networks (LR-WPANs) with a focus on 

enabling wireless sensor networks. WPANs are used to convey information over relatively short 

distances. Unlike wireless local area networks (WLANs), connections effected via WPANs 

involve little or no infrastructure. This feature allows small, power-efficient, inexpensive 

solutions to be implemented for a wide range of devices (2). 

The standard is characterized by maintaining a high level of simplicity, allowing for quick 

application software development that can operate with a wide variety of different sensors. 

4. Provoked Electronic Fault Data 

Figure 6 shows current data for a PEFT test performed on the elevation drive control circuit fuse. 

The initial spike in the data signifies the initiation of the PEFT as the elevation of the gun is 

driven to its hard stop at 60 degrees above horizontal. A second increase in current levels at 

26 seconds signifies a precursor to the tripping of the fuse. The fuse trips at 32 seconds, and is 

illustrated in the data by the sharp drop in current to 0 amps. When the fuse trips, no current can 

pass through, and this renders the CROWS system inoperable. This fuse-current data gives a 

clear indicator that may be used to predict what causes the fuse to trip in electronic system 

components. However, different indicators may be required to properly evaluate a potential fault 

and initiate preventive measures prior to component failure. 
7 

Figure 6. Current data acquired for a faulty fuse on the elevation 

control circuit card. 

Figure 7. Ambient temperature data for a faulty fuse and surrounding 

circuitry on the elevation control circuit card. 

Figure 7 shows fuse temperature of the elevation drive control circuit during the same PEFT. 

There is about a 7 second delay in the correspondence of the measured fuse temperature to the 

current data. The temperature sensor is located on the external casing of the fuse, and the delay 

is caused by the thermal propagation in the casing. While the current data shows a shorter spike 

in current levels prior to tripping the fuse, the fuse temperature data has a steadier rise 

characteristic. The decline in fuse temperature indicates that the fuse has tripped and current is 

no longer flowing through it. The drop off time is also affected by the thermal propagation delay 

of the location of the temperature sensor on the fuse casing. 
8 

Figures 6 and 7 are two examples of the types of failure precursor data that the ARL PDSM 

needs to collect and transmit in real time to provide the PDCS with the ability to perform PD 

functions on the system being monitored. 

5. Conclusion 

There is a growing need for automated data acquisition in military systems driven by the 

implementation of PD analysis. The ARL PDSM is highly flexible and can be configured to 

monitor key data test points in a variety of electronic systems. By remaining transparent to the 

user, the PDSM can accurately acquire and transfer necessary data to a processing station 

without the need for manual data extraction. 
9 

6. References

1. XM101 Common Remotely Operated Weapon Station (CROWS). 

www.globalsecurity.org/military/systems/ground/m101-crows.htm. November 19, 2005. 

2. “IEEE Standard for Information technology—Telecommunications and information 

exchange between systems—Local and metropolitan area networks Specific requirements, 

Part 15.4: Wireless Medium Access Control (MAC) and Physical Layer (PHY) 

Specifications for Low-Rate Wireless Personal Area Networks (LR-WPANs)”. IEEE 

Computer Society, The Institute of Electrical and Electronics Engineers, Inc., New York, 

2003. 

3. Texas Instruments, 430 Day 2006, SCYYY001 – May 2006. 

4. Teas Instruments. MSP430x1xx Family, User’s Guide, 2006, SLAU049F. 
10 

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