Innovative Fusion Strategy for MEMS Redundant-IMU Exploiting Custom 3D Components

In recent years, the overall performances of inertial Micro-Electro Mechanical Sensors (MEMSs) exhibited substantial improvements to values very close or similar to so-called tactical-grade sensors. However, due to their high costs, numerous researchers are currently focusing on the performance enhancement of cheap consumer-grade MEMS inertial sensors for all those applications (as an example, small unmanned aerial vehicles, UAVs), where cost effectiveness is a relevant request; the use of redundancy proves to be a feasible method for this purpose. In this regard, the authors propose, hereinafter, a suitable strategy aimed at fusing raw measurements provided by multiple inertial sensors mounted on a 3D-printed structure. In particular, accelerations and angular rates measured by the sensors are averaged according to weights associated with the results of an Allan variance approach; the lower the noise figure of the sensors, the greater their weight on the final averaged values. On the other hand, possible effects on the measurements due to the use of a 3D structure in reinforced ONYX (a material capable of providing better mechanical specifications for avionic applications with respect to other solutions for additive manufacturing) were evaluated. The performance of a prototype implementing the considered strategy is compared with that of a tactical-grade inertial measurement unit in stationary conditions, exhibiting differences as low as 0.3 degrees in heading measurements. Moreover, the reinforced ONYX structure does not significantly affect the measured values in terms of both thermal and magnetic field while assuring better mechanical characteristics with respect to other 3D printing materials, thanks to a tensile strength of about 250 MPa and a specific stacking sequence of continuous fibers. Finally, a test conducted on an actual UAV highlights performance very close to that of a reference unit, with root-mean-square error in heading measurements as low as 0.3 degrees in observation intervals up to 140 s.