Design, Implementation and Calibration of Analog Gyro-Based Angular Rate Data Acquisition System for High-Spinning Rotation Rate Applications

High-precision angular-rate measurements in extreme spin environments require systems capable of handling very high rotation rates, rapid startup, and reliable operation under vibration and shock. However, most commercially available gyro-based Inertial Measurement Units (IMUs) provide measurement ranges limited to approximately ±2000°/s, which may be insufficient for high-speed spinning platforms such as spin-stabilized satellites and drilling systems. This work presents the design, implementation, calibration, and validation of a complete Data Acquisition System (DAS) based on the ADXRS649 analog gyroscope, supporting angular rates up to ±20,000°/s. The system integrates a 12-bit ADC within a dsPIC33 microcontroller, high-speed nvSRAM for continuous logging, and firmware enabling sensor self-testing, memory checks, synchronized sampling, and onboard processing. Operating at a configurable sampling frequency of 50 Hz, the proposed system provides approximately 20 min of continuous data recording. Custom hardware, including multilayer PCB design, signal conditioning, power management, a rugged metallic enclosure, and polyurethane potting, enhances mechanical robustness for operation under vibration and shock. Laboratory calibration over the angular-rate range of ±980°/s quantified the gyroscope bias and scale factor, while experimental validation using a high-speed rotary machine demonstrated stable rolling measurements and reliable data integrity at angular rates exceeding 2000°/s. The results demonstrate that the proposed analog gyro-based DAS provides a robust and cost-effective solution for ultra-high-spin applications and future multi-sensor integration.