Three Wire

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Sensing, Computing, Actuating

Lecture 4 - Bridge circuit / Strain

Exercise 1: mass airflow sensor


The mass airflow sensor of an injection engine measures the amount of air that enters the combustion
chamber through the air intake. Before injecting the right amount of fuel, the engine needs to know
exactly how much air comes into the cylinders. For this purpose, it is more important to know the
mass rather then the volume of the air. The density of the air varies depending on the temperature
and altitude at which the vehicle is operated. To measure the air mass, you can use a so-called
“hot wire mass airflow sensor” (see Figure 1). In this sensor, the air is heated using a hot wire. In
the case of non-moving air, the air on both sides of the heating element will be heated to the same
temperature. Both RTDs (R3 and R4 ) measure in that case the same temperature1 . As soon as the
air starts moving, the temperature will rise at one RTD, whereas it lowers on the other RTD. The
change in temperature is related to the density and flow-speed of the air (and therefore with the mass
of the air).

vo

R1 R2
Vr

airflow T1 T2

heater

Figure 1: Mass airflow sensor.

The circuit in Figure 2 is used to measure a temperature difference between 0◦ C and 100◦ C in the
range of -60◦ C till +100◦ C. The maximal error in the measured temperature should be less then 1◦ C.
The resistors R3 en R4 are both temperature dependent resistors (RTDs). Both RTDs are of the
same type: PT100 with R0 = 100 Ω and α = 0.004/◦ C at 0◦ C. The dissipation constant δ of the air
varies (depending on the air density and flow-speed) between 1 mW/K and 4 mW/K.

Figure 2: Electrical equivalent circuit of mass airflow sensor.

1 In a practical implementation it is possible to integrate the heater with one of the RTDs.

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Eindhoven University of Technology Electrical Engineering

(a) Show that the output voltage of the bridge is equal to:

kα (T1 − T2 )
vo = Vr
(1 + k + αT1 ) (1 + k + αT2 )

with k = R1 /R0 = R2 /R0 .


(b) Show that the absolute error in the temperature difference due to the non-linearity of the circuit is
equal to:

α (T1 + T2 ) (k + 1) + α2 T1 T2
 = (T2 − T1 )
(1 + k + αT1 ) (1 + k + αT2 )

(c) What values should the resistors R1 and R2 have such that the maximal error is always smaller then
0.1◦ C? (Hint: you may ignore the self-heating error in this question.)
(d) Which value should the supply voltage have such that the error due to self-heating is always less then
0.01◦ C? (Hint: ∆T = PD /δ = I 2 · R /δ)

Exercise 2: manifold absolute pressure sensor


The manifold absolute pressure (MAP) sensor measures the absolute pressure in the inlet manifold
of a fuel injected engine. The sensor generates a signal proportional to the absolute pressure in the
inlet manifold. The engine’s electronic control unit (ECU) uses this information to determine the
ignition timing and the appropriate mixture of the fuel to optimize the combustion.
If the gas pedal is pressed causing the engine to work hard, the air pressure will rise in the engine. In
that situation, the engine needs to take in more air. More fuel should also be supplied to the engine
in order to keep the air/fuel ratio nearly constant. To be precise, the ECU will make enrich fuel
mixture a bit when the computer measures a heavy load. In this way, the engine is able to deliver a
bit more power when needed. At the same time, the ECU will delay the ignition timing of the engine
to prevent damage to its internals.
The engine needs to supply less power when the car is moving at a constant speed. In that situation,
the driver will apply less pressure on the gas pedal. The will cause a reduction in the air pressure
inside the engine. The MAP sensor detects this and the ECU will respond to this by adjusting the
fuel mixture ensuring that the car cruises most economically.
A MAP sensor can be realized using a number of strain gauges. Figure 3 shows the cross section
of such a MAP sensor. The sensor consists of a vacuum hollow room. At the top of the room, a
membrane is attached that changes shape when (air)pressure is applied. By attaching one or more
strain gauges to the member, it becomes possible to measure the change in the dimensions of the
membrane. Depending on the placement of the strain gauges, they are compressed or expanded when
pressure is applied to the membrane.

strain gauge membrane

sheet of glass vacuum

Figure 3: MAP sensor based on membrane and strain gauges.

Figure 4 shows the electrical equivalent circuit of such a MAP sensor with two strain gauges. In
addition to the strain gauges, the circuit contains also two fixed resistors. The Young’s modulus of
the membrane, E, is equal to 210 · 109 N/m2 . When unloaded, all four resistors have a resistance of
350 Ω. The strain gauges have a gauge factor of 2.10. To prevent any damage to the strain gauges,
the current through them should be limited to 10 mA.

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Eindhoven University of Technology Electrical Engineering

R1 R2=R0(1-x)
Vr vo
R4 R3=R0(1+x)

Figure 4: Electrical equivalent circuit of the MAP sensor.

(a) What is the maximal voltage, Vr , that can be placed over the bridge?
(b) Assume that the supply voltage of the bridge (Vr ) is equal to 7 V. What is the output voltage of the
bridge (vo ) when a pressure of 9.8 MPa is applied to the membrane?

Figure 5: Bridge with one strain gauge.

(c) The use of a bridge with two strain gauges might be to expensive from some applications. Therefore,
the circuit shown in Figure 4 can be replaced with a circuit that contains only one strain gauge (see
Figure 5). This strain gauge has a resistance of 350 Ω when unloaded and a gauge factor of 2.10. The
resistance of this strain gauge is given by R3 = R0 (1 + x). The maximal pressure that can be applied
to this strain gauge is 98.0 MPa. The strain gauge is used in a bridge circuit with three fixed resistors
(see Figure 5). The resistors R1 , R2 and R4 all have a resistance of 350 Ω. The supply voltage of the
bridge, Vr , is equal to 7 V. The output voltage of this circuit will show a non-linearity because the
circuit contains only one strain gauge. What is the maximal relative error when the output voltage
of the bridge (vo ) is assumed to have a linear dependency on the stress y with a sensitivity equal to
the sensitivity at y = 0?
(d) The resistance of a strain gauge changes when it is stretched. This change in resistance is caused by
two effects. Name both effects and explain which effect is important in metals and in silicon strain
gauges.
(e) Strain gauges are used amongst others to measure torque. Assume that you want to measure the
torque on a cylindrical tube using strain gauges. Where should the strain gauges be placed and why?

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