Sensors and Actuators

Course: Automotive Electronics

Unit: II

Chapter Nos.: 03

Faculties In charge: P. C. Nissimagoudar

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Case study

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Control System

ECU CAR

Sensors
In any control system,

Sensors provide measurements of important plant variables in a format suitable for the
digital microcontroller.

Actuators are externally operated devices that regulate inputs to the plant that directly
control its output.
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Contd..

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Contd.

Automotive manufacturers are continuously increasing the

use of electronics systems to,

ü Improve vehicle performance

ü Safety
ü Passenger comfort.

Sensors and actuators are integrated with automotive

control computers to help optimize vehicle performance
while improving reliability and durability.
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Selection Criteria

ü What is to be measured
ü Magnitude, range, dynamics of measured quantity
ü Required resolution, accuracy
ü Cost
ü Environment
ü Interface Requirements
ü Output quantity (voltage, current, resistance,…)
ü Sensitivity
ü Signal conditioning
ü A/D requirements (#bits, data rate)
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Sensors and Actuators

On completion of this session the student would have understood

ü The various sensors and actuators that are used in automotive

electronics

ü Their working principles

ü Their various uses in automotive electronic systems

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To kick start……

Then this should work…….

JUGAAD
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Contd.

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Contd..

Physical System

Speed and Acceleration

Distance and Throttle
sensor

Cruise Control
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Typical Sensors: Car

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Contd..

Sample: Sensor mounting

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Sensors and Actuators

The superset of variables sensed in engine control includes the following:

1. Mass air flow (MAF) rate

2. Exhaust gas oxygen concentration (possibly heated)
3. Throttle plate angular position
4. Crankshaft angular position/RPM
5. Coolant temperature
6. Intake air temperature
7. Manifold absolute pressure (MAP)
8. Differential exhaust gas pressure
9. Vehicle speed
10. Transmission gear selector position

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Typical Electronic Engine Control System

Throttle position Mass air flow Exhaust gas Exhaust gas

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sensor School of ECE oxygen recirculation 15
Mass
AIRAir FlowRATE
FLOW Sensor (MAF)
SENSOR
ü The correct operation of an electronically controlled engine operating with
government-regulated exhaust emissions requires a measurement of the mass
flow rate of air (Rm) into the engine.

ü The Mass Air Flow Sensor (MAF) is a computer-controlled sensor that calculates
the volume and density of the air taken in by the engine.

ü This is normally mounted as part of the air cleaner assembly, where it measures
air flow into the intake manifold.

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Mass Air Flow Sensor (MAF): contd..

ü The MAF sensor is a variation of a classic air flow sensor that was known as a hot wire
anemometer: Wheatstone bridge configuration
ü The BC counts (in binary) at the instantaneous frequency of the v/f, which is
proportional to the amplifier output voltage vf , which in turn varies with mass air
flow rate.

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Air Mass Flow sensor

ü Contains a hot film inside

ü Hot film Cools down as air enters
inside
ü Voltage increases as it cools down
ü ECM determines air quantity based
on this

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Manifold Absolute Pressure Sensor (MAP)

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 Contd..

Circuit Diagram
for
MAP Sensor
Using
Strain Gauges

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Engine Crankshaft Angular Position Sensor
ENGINE CRANKSHAFT ANGULAR POSITION SENSOR
ü Crankshaft angular position is an important variable in automotive control
Magnetic
systems, Reluctance
particularly Position
for controlling Sensor
ignition timing and fuel injection timing.
ü It is desirable to measure engine angular position with a non contacting sensor to
avoid mechanical wear and corresponding changes in accuracy of the
measurement.
ü The two most common methods for noncontact coupling to a rotating shaft
employ magnetic fields or optics.

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Contd..

Magnetic Reluctance Position Sensor

ü ThisMagnetic
sensor consists of a permanent
Reluctance magnetSensor
Position with a coil of wire wound around it. A steel disk
that is mounted on the crankshaft
ü The passage of each tab can correspond to the TDC position of a cylinder on its power stroke

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Contd..

ü The change in magnetic flux induces a voltage, Vo, in the sensing coil that is
proportional to the rate of change of the magnetic flux.
ü Vo, begins to increase from zero as a tab begins to pass between the pole pieces,
reaches a maximum, then falls to zero when the tab is exactly between the pole pieces

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 Engine Speed Sensor
Timing Sensor for Ignition and Fuel Delivery
ü Engine speed can be calculated in a number of ways. Digital circuits use counters and
crankshaft sensors to calculate actual engine speed.

Crankshaft Position
Sensor

As the camshaft rotates, the notch passes under the sensor once for every
two crankshaft revolutions. The magnetic flux abruptly decreases, then
increases as the notch passes the sensor. This generates a voltage pulse that can
be used
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School purposes.
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 Contd..
Hall-Effect Position Sensor
Hall-Effect Position Sensor
The Hall element
As mentioned is a thin
previously, oneslab of semiconductor
of the main disadvantages material
of that is placed between the
the magnetic
magnetssensor
reluctance so it can
is itssense theoutput
lack of magnetic
when flux
thevariations as the
engine isn’t tab passes.
running. A constant
A crankshaft
current
position is passed
sensor through
that avoids thisthe semiconductor
problem in one position
is the Hall-effect direction, and a voltage is
sensor.
Thisgenerated thatbe
sensor can varies
usedwith the strength
to measure of the
either magnetic
camshaft flux. or crankshaft
position
position.

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Contd..

ü In the optical crankshaft position sensor, a disk coupled to the crankshaft has holes
to pass light between the LED and the phototransistor.
ü An output pulse is generated as each hole passes the LED.

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Throttle Angle Sensor
THROTTLE ANGLE SENSOR

ü The throttle plate is linked mechanically to the accelerator pedal

ü Most throttle angle sensors are essentially potentiometers
ü A potentiometer consists of a resistor with a movable contact

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Temperature Sensors

Temperature Sensors in ECM

• Engine Coolant Temperature Sensor

• Air Intake Temperature Sensor

• EGR Temperature Sensor

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Engine Coolant Temperature Sensor (ECT)

• Senses the coolant temp.

• Tells the ECM about the present temp.
• ECM instructs the radiator fan to turn
on , if temp exceeds the threshold.
• The measuring range is usually from -
40° to + 130°C.

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Contd..

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Contd..

Thermistors

ü Commonly used for temperature measurement on vehicles.

ü They are made out of semiconductor materials such as cobalt or nickel

oxides.

ü Change in temperature causes change in change in resistance of the

thermistor.

ü Most of the thermistors are of the negative negative temperature

coefficient (NTC) type

ü Resistance range – Several Kilo Ohms at 0oC to a few hundred Ohms

hundred Ohms at 100o C. Thus it can be more sensitive.
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Contd..

NTC Thermistor ‘s curve

( temp v/s Resistance)

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Oxygen Sensors

ü It is also known as the 02 sensors.

ü It is situated in the exhaust pipe.

ü The sensor determines how much oxygen is left in the exhaust.

ü It will point out whether the fuel is burning rich or lean.

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Contd..

Stoichiometry
ü Stoichiometry in automotive terms is the principle that refers to the “ideal” air to fuel
ratio being consumed in the cylinder.

ü At 14.7 pound of air to 1 pound of fuel, even pre-converter HC, CO and NOX exhaust
gases will be at their lowest levels.

ü However, no vehicle can maintain a precise 14.7:1 mixture.

ü Constant changes in the throttle position, engine load, and vehicle speed cause the
mixture to vary almost constantly.

ü The feedback system has to adjust the mixture constantly to keep the mixture near
optimum levels.
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Contd..

Stoichiometry
ü The system keeps the air/fuel mixture close to the ideal by constantly switching back
and forth on either side of stoichiometry.

ü The engine management system is responsible for maintaining stoichiometry allowing

the catalytic converter to operate at maximum efficiency while maintaining minimal
emissions.

ü The engine management system uses an oxygen sensor in the exhaust to determine if
the air/fuel mixture is rich or lean and adjusts to compensate.

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Contd..

Oxygen Sensor Operation

The oxygen sensor plays a critical role in providing optimum engine performance with
minimal emissions.

There are three basic types of oxygen sensors. They are the:

• Zirconia
• Titania
• Air Fuel

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Contd..

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Contd..

ü This sensor is often called a lambda sensor from the Greek letter lambda (l), which is
commonly used to denote the equivalence ratio:

ü Whenever the air/fuel ratio is at stoichiometry, the value for l is 1.

ü When the air–fuel mixture is too lean, the condition is represented by lambda greater than one
(denoted l > 1).
ü When the air–fuel mixture is too rich, the condition is represented by an equivalence ratio of
lambda less than one (l < 1).

ü The two types of EGO sensors that have been used are based on the use of active oxides
of two types of materials.
ü Zirconium dioxide (ZrO2)
ü Titanium dioxide (TiO2).
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Contd..

ü The zirconium dioxide EGO sensor uses zirconium dioxide sandwiched between two
platinum electrodes. One electrode is exposed to exhaust gas and the other is exposed to
normal air for reference.
ü The ZrO2 has a tendency to attract the oxygen ions, which accumulate on the ZrO2
surface just inside the platinum electrodes.
ü The platinum plate on the air reference side of the ZrO2 is exposed to a much higher
concentration of oxygen ions than the exhaust gas side.
ü The air reference side becomes electrically more negative than the exhaust gas side;
therefore, an electric field exists across the ZrO2 material and a voltage, Vo, results.

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Contd..

Typical Voltage
Switching
Characteristics of
EGO Sensor

Ideal EGO Switching

Characteristics

Typical EGO Sensor

Characteristics

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Knock Sensor

ü What are Knocks?? - high frequency vibrations caused by detonation, or the

premature burning of fuel inside an engine's cylinders

ü it can be described generally as a rapid rise in cylinder pressure during combustion.

ü It occurs most commonly with high manifold pressure and excessive spark advance. It
is important to detect knock and avoid excessive knock; otherwise, there may be
damage to the engine.

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Contd..

How it works - Piezoelectric effect

ü Knock Sensors generate a voltage when
vibration is applied to them utilizing the
piezoelectric effect

ü Due to the vibration, a counter weight

inside the sensor is applying pressure on
the piezo element, this pressure creates
an electric charge in the piezo element
which is the output signal of the sensor.

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 Contd..

ü Once signs of knocking are detected, the knock sensor sends a voltage
signal to the engine management computer, which retards the spark
timing slightly to avoid detonation.
Benefits
•Vehicle engines work more efficiently and produce more
power when operating near the detonation limit.

•Although simple, knock sensors allow optimum engine

performance and protect the engine from potential damage
caused by detonation.

Challenges

• Piezoelectric elements can be sensitive to more than one physical dimension Ceramic materials
lack long term stability
• Sensor
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of ECE
Automotive Engine Control Actuators

ü An actuator is a device that receives an electrical input (e.g., from the engine
controller) and produces a mechanical or thermal (or other) output.
ü Some of the actuators are:
ü Solenoids
ü DC Motors
ü Stepper motors
ü Hydraulic/Pneumatic
ü Piezo Actuators and so on..

Schematic Drawing of
a Solenoid

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Contd..

ü One of the examples of solenoid actuator is the one

used in Fuel injector Fuel injector.
ü A typical fuel injector solenoid has the following:
ü Stroke: 0.1mm
ü Open period range: 1.5 to 10.0 ms.
ü Coil resistance : 16 Ω
ü Time taken by an injector to open and close is
critical in fuel injection.
ü The induction of the coil plays an important role in
the reaction time for the solenoid. (Higher
inductance -> longer reaction time, ballast
resistors)
ü Another application of solenoid actuator is for
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Contd..

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 Contd..
Fuel Injection

Schematic Drawing
of
Fuel Injector

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Contd..
Fuel Injector Signal

Pulse Mode Fuel

Control Signal to Fuel
Injector

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Contd..

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Motors

Throttle Valve

Steeper Motor Control

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 Contd..

• A stepper motor is an electromechanical device it converts electrical power into

mechanical power.
• The stepper motor uses the theory of operation for magnets to make the motor
shaft turn a precise distance when a pulse of electricity is provided.

Advantages of Stepper Motor:

• The rotation angle of the motor is proportional to the input pulse.
• The motor has full torque at standstill.
• Precise positioning and repeatability of movement since good stepper motors have
an accuracy of 3 – 5% of a step and this error is non cumulative from one step to
the next.
• Excellent response to starting, stopping and reversing.
• The motors response to digital input pulses provides open-loop control, making
the motor simpler and less costly to control.
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Hydraulic/Pneumatic

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Contd..

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Summary

ü The various sensors used for ECM applications were studied

with its working principles.

ü The mounting of these sensors and its functionality were

studied

ü Actuators for specific applications related to ECM were studied

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 Ignition System

THANK YOU

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