Escolar Documentos
Profissional Documentos
Cultura Documentos
AEL2501
PEMP
AEL2501
Session Objectives
On completion of this session the delegates
would have understood :
Th
The various
i sensors andd actuators that
h are usedd
in automotive electronics,
Their working principles,
Their various uses in automotive electronic
systems
1
PEMP
AEL2501
Topics
Introduction to automotive electronics
Automotive sensors and actuators
Selection criterion
Different types of sensors
Actuators
A case study Honda City car
PEMP
AEL2501
2
PEMP
AEL2501
PEMP
AEL2501
Sensor-- Input
Sensor Microcontroller Actuator-- Output
Actuator
3
PEMP
AEL2501
Measurement System
SIGNAL
SENSOR
CONDITIONING
A/D CPU
PEMP
AEL2501
Selection Criteria
What is to be measured
Magnitude, range, dynamics
of measured quantity
Required resolution, accuracy
Cost
Environment
Interface Requirements:
Output quantity (voltage,
current, resistance,)
Sensitivity
Signal conditioning
A/D requirements (#bits, data
rate)
4
PEMP
AEL2501
Thermistors
Commonly used for temperature measurement
on vehicles.
They are made out of semiconductor materials
such as cobalt or nickel oxides.
Change in temperature causes change in
resistance of the thermistor.
Most of the thermistors are of the negative
temperature coefficient (NTC) type
Resistance range Several Kilo Ohms at 0oC
to a few hundred Ohms at 100o C. Thus it can
be more sensitive.
PEMP
AEL2501
5
PEMP
AEL2501
Temperature sensor
Application Engine management
Function Registration of temperature of
coolants,
l fuel
f l andd air
i
Installation Engine block, coolant
circuit, air-intake tract
Sensing principle NTC technology (hot
conductor, negative temperature
coefficient)
Technical data
Temperature range: -40C...+150C
Time constant: 5 s...44 s (depending on type)
Accuracy: 0.8 K at 100C 1.5 K at 20C
PEMP
AEL2501
Thermocouples
When two dissimilar metals are joined together, the
thermocouple junction is formed.
Among the two junctions used, one of the junctions is kept
at a constant known
kno n temperature
temperat re where
here as the other at the
temperature to be measured.
Ex: 70% platinum & 30% rhodium alloy known as B Type
, Has a range of 0 15000C.
Used for measuring Exhaust Gas and turbocharger
temperatures in a vehicle.
6
PEMP
AEL2501
Magnetic Sensors
Variable Reluctance (VR) Sensors
Used mainly for speed and position
measurements of rotating members. ( Ex:
crank shaft speed
p and position
p sensing)
g)
The variable reluctance sensor is an electro-
magnetic device consisting of a permanent
magnet surrounded by a winding of wire.wire
The sensor is used in conjunction with a
ferrous target that either has notches or teeth.
Rotation of the target wheel near the tip of the
sensor changes
g the magnetic
g flux, creatingg an
flux,
analog voltage signal in the sensor coil.
Though the voltage may vary depending on the
speed of rotating member, the frequency is
used for measurement.
PEMP
AEL2501
A common method of
converting this signal into a
useful signal for interfacing
with
ith other
th didigital
it l circuit
i it isi by
b
using a Schmitt trigger circuit.
Another method is by using a
quenched oscillator circuit as
shown in the figure. This circuit
has good resistance to
interference
interference.
7
PEMP
AEL2501
Typical Applications:
Ignition system engine speed
and position
Speed sensing for
electronically
l t i ll controlled
t ll d
transmissions
Vehicle speed sensing
Wheel speed sensing for ABS
and traction control systems
PEMP
AEL2501
8
PEMP
AEL2501
Variable resistance
These sensors are mainly used for sensing larger change in
position.
position
Example: The throttle position sensor, which is a
potentiometer.
It is supplied with a stable 5 Volts DC.
The wiper is driven by the throttle shaft
shaft. Thus , the voltage from
the wiper contact will be proportional to the throttle position.
position
In many cases,throttle potentiometer is used to indicate the rate
of change of throttle position
position. This information is used in
implementing acceleration enrichment or over-run fuel cut-off.
PEMP
AEL2501
9
PEMP
AEL2501
Accelerator-pedal module
Application Engine management
Function Registering the driver's wishes
(d
(demand d for
f torque))
Installation Passenger compartment
Sensing principle Hall effect or
potentiometer
Technical data
Supply voltage: 5 V
Measuring
M i range: customer-specific
t ifi pedal
d l travel
t l
40 mm ... 80 mm
Temperature range: -40... +80C
Output signal: analog
PEMP
AEL2501
Pressure sensor
Application Engine management
Function Barometric pressure
measurement
Installation Printed circuit board
(PCB)
Sensing principle Silicon
micromechanics with integrated
evaluation circuit
Technical data
Measuring range: 60 kP...
kP
115 kPa
Analog output: 2.37 V ...
4.54 V
Temperature range: -
40C ... +130C
M.S Ramaiah School of Advanced Studies - Bangalore 20
10
PEMP
AEL2501
Technical data
Supply
S l voltage:
lt 5V
Power consumption: 9 mA (typical)
Measuring range: < 400 kPa (absolute)
Response time: < 1 ms
Temperature range: -40... +130C
PEMP
AEL2501
Acclerometers
Piezoelectric accelerometers are generally used as knock
sensors.
A piezoelectric accelerometer is a seismic mass
accelerometer using a piezoelectric crystal to convert the
force on the mass due to acceleration into an electrical
output signal.
signal The piezoelectric crystal acts not only as a
transducer but also as the suspension spring for the mass.
When used for knock detection, they also pick up other
vibrations, these are kept at minimum by looking for a
knock a few degrees before and after the TDC.
11
PEMP
AEL2501
PEMP
AEL2501
Knock sensor
Application Engine management
Function Registration
g of structure-borne vibrations
(knocking). Knocking combustion can damage the engine.
The data from the knock sensor enables counter-measures
to be undertaken.
Installation Engine block
Sensing principle Piezo-electrical
Technical data
Sensitivity at 5 kHz: 30 6 mV/g
Linearity at 5-kHz value: 10 %
Frequency range: 3 kHz ...22 kHz
Temperature range: -40...+150C
M.S Ramaiah School of Advanced Studies - Bangalore 24
12
PEMP
Application
ESP
ABS
Safety (airbag systems)
Function Registration of accelerations in
the X, Y and Z axes
Installation
Integration into circuit board (SMD)
Remote sensor
Sensing principle Surface mechanics
(capacitive)
Technical data Measuring range (airbag)
SMD element: 2 g...250 g
Peripheral sensor: 50 g...250 g
Sensor output: analog or digital
Temperature range: -40C...+120C
M.S Ramaiah School of Advanced Studies - Bangalore 25
PEMP
AEL2501
Yaw-rate sensor
Application ESP
Function Registration of the rotational movement of the
vehicle around its vertical axis
Installation Passenger compartment
Sensing principle Micromechanics, CAN interface
Technical data
Yaw-rate sensor measuring range: 100/s
Acceleration sensor measuring range: 1.8 g
Initialization time: <= 1.0 s
Temperature range: -40C...+85C
Supply voltage: 8.2
8 2 V...16
V 16 V
Nominal voltage: 12 V
13
PEMP
AEL2501
PEMP
AEL2501
14
PEMP
AEL2501
PEMP
AEL2501
15
PEMP
AEL2501
Oxygen Sensor
The oxygen sensor provides a closed loop
feedback for the engine management
system to control the air fuel ratio.
ratio
OBD II Requirement
The amount of oxygen sensed is directly Sensor 1 Air/Fuel Ratio
Sensor 2 Catalytic Converter Efficiency
related to the mixture strength or air-fuel
ratio.
Normalized air-fuel ratio() = Current air-
fuel ratio / Stoichiometric air-fuel ratio
The air-fuel
air fuel ratio 14.7:1
14 7:1 by mass is
known as a Lambda (() value of one.
one
PEMP
AEL2501
16
PEMP
AEL2501
PEMP
AEL2501
17
PEMP
AEL2501
Actuators
Actuator is a general term to describe a control mechanism.
An actuator is part of an open
open--loop or closed
closed--loop control
system which connects the electronic unit with the process.
The actuator consists of a transformer and a final-control
element.
Each positioning signals are converted to mechanical output.
PEMP
AEL2501
18
PEMP
AEL2501
Solenoid Actuators
A solenoid is defined as a coil of wire commonly in the
form of a long cylinder that when carrying a current
resembles a bar magnet so that a moveable core
(armature) is drawn into (pulled
(pulled--in) the coil when a
currentt flows.
flows
fl
A more simple definition is that a solenoid is a coil and
a moveable iron core used to convert electrical energy
into mechanical energy.
Normally, the movement of the core compresses a
spring.
On power-off, the armature returns back to its normal
position.
ii
The stroke of the armature varies from fraction of a mm
to several mm depending on application.
There are two main categories of solenoids:
Rotary rotary motion of the armature
Linear linear motion of the armature
M.S Ramaiah School of Advanced Studies - Bangalore 37
PEMP
AEL2501
19
PEMP
AEL2501
PEMP
AEL2501
Relays
Electromagnetic switches
20
PEMP
AEL2501
DC Motors
Permanent magnet motors are commonly used in
automobiles as they are versatile.
The rotary speed (RPM) of the motor which is usually high is
suitably
i bl modified
difi d through
h h gearing
i down
d (i
(increase in
i torque)) or
other mechanisms to get the desired rotary or linear motion.
For applications such as power electric steering, the
options available are :
Brushless DC (BLDC)
Switched-reluctance motors (SRM)
The BLDC motor has permanent magnets that are susceptible to
high temperature complications (automotive temperatures -40 to
125C.)
PEMP
AEL2501
Typical Specifications of a DC
Motor:
Voltage: 12V DC
No load speed: 9000r/min
10%
No load current: 4A
Load: 7650r/min 10%,
0.226Nm, 19A
Rotation direction:
clockwise
21
PEMP
AEL2501
PEMP
AEL2501
Ex:
22
PEMP
AEL2501
Windows Motors
PEMP
AEL2501
EPB Actuator
23
PEMP
AEL2501
Stepper Motors
Stepping motors:
Permanent magnet Type
Permanent magnet motors
usually
ll have
h two
t
independent windings, with
or without center taps.
Center-tapped windings are
used in unipolar permanent
magnet motors.
Variable reluctance Type
Variable reluctance motors
usually have three
(sometimes four or five)
windings, with a common
return.
PEMP
AEL2501
Angular resolution:
The coarsest motors typically turn 90 degrees per
step
High resolution permanent magnet motors are
commonly able to handle 1.8 or even 0.72
degrees per step.
With an appropriate
i t controller,
t ll mostt permanentt
magnet and hybrid motors can be run in half-
steps, and some controllers can handle smaller
fractional steps or microsteps.
For both permanent magnet and variable
reluctance stepping motors, if just one
winding of the motor is energized, the rotor
(under no load) will snap to a fixed angle
and then hold that angle until the torque
exceeds the holding torque of the motor, at
which point, the rotor will turn, trying to
hold at each successive equilibrium point.
They do not have high starting torque
torque.
M.S Ramaiah School of Advanced Studies - Bangalore 48
24
PEMP
AEL2501
Applications:
Idle speed air by-pass
Electronic Throttle control
Speedometer display drives
Adaptive Front-lighting
(AFS) system, etc. Digital Instrument Cluster
Adaptive Front-lighting System
PEMP
AEL2501
Piezo Actuators
A piezo actuator enables response times of just a
few Tenth of a millisecond.
It consists of many crystal layers that expand by
a few hundredths of millimeters when voltage is
applied.
One of the automotive applications of the Piezo
actuators is in Diesel Unit Injection Systems.
Example:
Stacked actuator
Motion up to 100 m
Maximum load 3500 N
Very high stiffness up to 200 N/m
Voltage -10...150V (multi-layer)
25
PEMP
AEL2501
Air Filter
Alternator
PEMP
AEL2501
IAT Sensor
MAP Sensor
26
PEMP
AEL2501
HONDA City Engine sensors
Purge Control Solenoid Throttle Body
Purge Control Valve
part of the
evaporative
emission control
system.
Wiring Harness TPS- Throttle
Position Sensor
measures the throttle
valve opening.
TPS
ISC Solenoid
Idlingg speed
p control
ISC Solenoid solenoid controls the
flow of air during
idling of engine to
control the speed of
engine within the
specified range.
M.S Ramaiah School of Advanced Studies - Bangalore 53
PEMP
AEL2501
Starter Motor
Fuel Injector
27
PEMP
AEL2501
PEMP
AEL2501
28
PEMP
AEL2501
PEMP
AEL2501
CAM Shaft
The cam shaft sensor is mounted on the engine near the cam
shaft.
It is a Hall effect transducer which generates an electrical
signal that is proportional to the rotation of the cam shaft.
M.S Ramaiah School of Advanced Studies - Bangalore 58
29
PEMP
AEL2501
Knock Sensor
Knock sensor mounting
PEMP
AEL2501
30
PEMP
AEL2501
Oxygen Sensors
The oxygen sensors are
also known as the
Lambda Sensors.
Sensors
They
Th are located
l t d ini the
th
exhaust gases leaving
the cylinder.
They measure the
amount of oxygen
present in the exhaust
p
gases.
This information is used
to control the emission
PEMP
AEL2501
Summary
Various types of automotive sensors and
actuators have been discussed in terms of
working
ki principles,
i i l applications
li ti in
i
automotive electronic systems.
31