Bosch Power-train / Exhaust Sensors Overview - IIT Kanpur · PDF file · 2016-09-07Bosch Power-train / Exhaust Sensors Overview ... Working Principle : Wheatstone Bridge(Pressure

Bosch Power-train / Exhaust Sensors Overview

Aravind KPowertrain & Exhaust Sensor Division

Bosch Sensors Overview/Training:

Internal | DGS-ES/ENG-IN_Ak | 31/08/2016

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© Bosch Limited 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

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Definition of Sensor

A sensor is a device which

measures a physical variable and

converts it into a electrical variable

which can be read by an

observer/control unit

E.g.:

‒ a mercury thermometer converts

the measured temperature into

expansion and contraction of a

liquid which can be read on a

calibrated glass tube.

‒ a thermocouple converts

temperature to an output voltage

which can be read by a voltmeter


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Diesel Engine Layout | CV



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Mounting Location (spark ignited engine - PC)

Exhausttemp. sensor*

Carbon canister

Air mass meter

Camshaftphaser*

Ignition coil/spark plug

Boost pressuretemp. sensor

Acceleratorpedal modul

Temp.sensor

Fuelpumpmodule

Oxygensensor

Throttledevice(ETC)

ETC = Electronic Throttle ControlCamshaft phaser:intake and/or exhaust phasing

Ambientpressuresensor

Canisterpurge valve

Nonreturnvalves

Turbo-vacuumreservoir

Speedsensor

Injector

Turbocharger

Solenoidvalve

Phasesensor

WasteGate

WasteGate actuator

Oxygensensor

Pre catalyst

Main catalyst

Pressuresensor

Knocksensor

Fuel rail

Highpressurepump

Solenoidvalve

Dumpvalve

* optionBosch components

specifically for DI

Electronic control unit

DiagnosislampDiagnosisinterfaceImmobilizer

CAN

SCV1

1 swirl control valve (on/off or continious)

Intercooler



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Rotational Speed Sensor Crank

(RSC, DG)

High Pressure Sensors

(RPS, HPS)

Camshaft Position Sensor

(CPS, PG)

Oxygen Sensor

(LS)

Particulate Matter

Sensor

(EGS-PM)

Mass Air Flow Sensor

(HFM)

NOx Sensor

(EGS-NX)

Knock Sensor

(KS)

Low Pressure Sensors

(LPS)

Temperature Sensor

(TS)

Pressure Based Air

Flow Meter

(PFM)

Speed Sensor Turbo Charger

(RS-T1)

Bosch exhaust and powertrain sensor portfolioSensor portfolio overview

Exhaust & powertrain sensors

Throttle Position

Sensor

(TPS)

Exh Temp Sensor

(EGS-T)


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Powertrain sensor portfolio DGS-ESProduct Area | Powertrain Sensors

Pressure

sensors

(xPS)

Air mass

sensors

(xFM)

Speed &

position

sensors

(RSx, CPS,

TPS)

Knock

sensors

(KS)

Temperature

sensors

(TS)


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Features

Application

Low Pressure Sensor - LPS

Silicon micromechanics, 1-chip-concept

Standardized design for different applications

Absolute, differential, relative pressure applications

Pressure range 0 …… 400 kPa Max-absolute

Operating temperature range -40 …. 130°C(optional 150°C)

Working Principle : Wheatstone Bridge(Pressure transducers)

Measures Intake Manifold Air Pressure & Temperature

Measures Boost pressure.

DSS3

DSS3-TF

Facts and Figures

SOP : 2006

SOP(India) : 2010

Mounting Location

Intake manifold

After turbo-charger


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Functional Principle

0

5

0 115

Absolutdruck pabs in kPa

Au

sg

an

gssp

an

un

g U

A in

V

0,4

10

4,65

Use : To measure Intake mainfold pressure & Temp.

UA = output voltage in V

US = supply voltage in V

pabs = absolute pressure in kPa

c0 = -0,1/105

c1 = 0,85/105 kPa-1

UA= (c1pabs+c0)US

Transfer function and accuracy

(e.g. 10 - 115 kPa)

0

0,5

1

1,5

2

2,5

3

3,5

4

-50 150

Temperatur t in °C

Fakto

r

10-40 85 130


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Differential Pressure Sensor DS-D2Features

Application

Pressure ranges from 0 to 125 kPa

Silicon MEMS Sensor chip (pressure transducer with integrated electronic circuit) on hybrid ceramic

1-Chip concept with mechanical differential pressure measurement

Sensing element protected by media resistant gel

Media robust design for DPF application

Operating temperature range -40 …. 130°C(optional 150°C)


Measures pressure & temperature across EGR unit & DPF.Facts and Figures

SOP : 2006

EGR – Exhaust Gas Re-circulation

DPF – Diesel Particulate Filter

Mounting Location

Across DPF

After EGR


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Features

Stainless steel sensing element with metal thin film strain gages

Digital circuit concept with analogue output signal

Modular, compact design, small overall height

Pressure ranges: 150, 180, 200, 220, 240, 270 Mpa

Temperature range -40°C/+130°C(optional 150°C)


Measures the pressure of fuel in the rail – Diesel Application.

Measures the pressure of fuel in GDI application.

Application

Facts and Figures

SOP : 2001

High Pressure Sensor

Mounting Location

On the fuel rail


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Sensorelement

Pressure14 MPa0

0,2

0,5

4,5

V

Ou

tpu

t V

olta

ge

4,8


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Hot Film Air Mass sensor (HFM8)

Features

Reduced air mass tolerances and improved pulsation behavior New part tolerance: 1.5%*

Lifetime tolerance: 3.5%*

Pulsation error : 6%*

Flexible modular system: Optional integration of additional pressure-, temperature- and humidity-

sensor / SENT or FAS interface / 5V or 12V supply voltage / Optional

applicable digital signal filters, Optional Chipheating function

Reduced power consumption < 20mA (for standard sensor)

Working Principle : Wheatstone Bridge(Thermistors)

Measures the mass(kg/hr) & temperature of Intake air.

Humidity & pressure measurement options available.

Application65

34

9

Measures in mm

Facts and Figures

SOP : 2014 Mounting Location

After Air Filter in the AISAIS – Air Intake System


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T2

T1

0

T

1

2

4

5

6

7

8

9

10

Forwardflow

Back

300 400 500

3

Fre

qu

en

cy (

kH

z)

flow

100 200 600

Mass Air Flow (kg/h)

Output signal as a function of

Airmass


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Pressure Based Air Flow Meter - PFM

Features

Air flow measurement using dynamic pressure

Engine near, compact mounting position after charge air cooler

Measurement of dynamic pressure (Pd), reference pressure (PS) and temperature (T)

Calculation of the air mass on basis of Bernoulli-equation

Suitable for off-highway application

Working Principle : Bernoulli equation + Ideal Gas equation +

Conservation of mass

Application

Facts and Figures

SOP(pilot): 12/2017

Preliminary Design – Functional Sample (PFM)

Measures the mass(kg/hr) & temperature of Intake air.

Mounting Location

After Air Filter in the AIS

AIS – Air Intake System

Ptot

T

Ps


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Functional principle

Robust measurement of air mass flow

Measurement of dynamic- (Pd) and reference pressure (Ps) by two pressure sensors

(Δp and Ps); measurement of temperature (T)

Fig. acc. To Prandtl tube principle

(Ps)

Temperature

(T)

Air

Air mass calculation:

Integrated Sensors :


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Knock Sensor – KS-4

Features

Broadband type, 5 to 22 kHz

Linear characteristics over large frequency range

30mV/g at 5 kHz, active output

Standard version: -40 ... 130°C

Extended heat version: -40 ... 150°C

Technology: piezo-ceramic ring

Engine protection from uncontrolled combustion

Working Principle : Piezo-electric.

Senses the engine-knocking/vibrations

Application

KS-4S

KS-4K

Facts and Figures


On Engine block near cylinders


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Characteristic curve U = f ( f )

mV/g

50

40

30

20

10

0 5 10 15 20 kHza Q/C = U excitation by acceleration

piezo effect


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Water/Oil Temperature Sensor

Features

Temperature range: -40°C ↔ +130°C (optional 150°C)

Supply voltage: 5V (only with series resistance)

Response time ((63): 20 …80°C): 10 …15 sec

Vibration proof: max. a(sin) = 300 m/s²

Isolation: 500V for 1 …3sec.

Durable against operating materials (fuel, oil, battery acid, ...)

Durable against water according DIN 40 050, IPX4K 9K

Working Principle : NTC – Negative temperature coefficient

Measures Engine coolant water / oil temperature

Application

Facts and Figures

SOP(India): 2011 Mounting Location

On Engine block for air cooled engines


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5 V

additional

resistor

e.g. 1 k

NTC

principle circuit diagram

Characteristic R=f(T)

10

100

1000

10000

100000

-40 -20 0 20 40 60 80 100 120 140

Temperature t in °C

Res

ista

nce

R in

Oh

m

- Electrical resistance changes with temperature (thermistor)- Resistance decreases when warming up


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Crankshaft Sensor DG-6

Features

Measures speed of the crank wheel/engine.

Application

2-wire Variable Reluctance principle

Speed range from 20 … 7000 rpm

Wide temperature range -40 ... 130°C(optional 150°C)

Working air gap range – 0.3 to 1.8 mm

Available as plug-in or cable type.

Typical application: Crankshaft sensor with 60-2 teeth target

Working Principle : Faraday’s law of electro-magnetic induction

Facts and Figures

SOP : 1993

SOP(India): 2010

Mounting Location

On Crank Wheel/fly wheel

Crank pulley


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Function principle Signal generation

Output versus speed Signal with a 60-2 target


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Crankshaft Sensor DG-23/DG-23i

Features

Measures speed of the crank wheel/engine.

Application

Direction rotation detection

Multi-Hall principle / single-track target wheel


High repeatability(± 0.04 °CRANK 1,3)

Wide speed range from 0 … 10000 rpm

Reverse speed range upto …. 5000 rpm

Working Principle : Hall Effect

Facts and Figures


On Crank Wheel/fly wheel

Crank pulley


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Speed Sensor for Turbo Charger - RS-T1

Features

Measures the speed of the turbo-charger

Application

Detection of each compressor blade up to 400 000 rpm T/C speed

Integrated high temperature electronics for best EMC behavior

Temperature range up to 200 °C (sensor head)

Frequency signal comparable to a speed sensor

No additional ASIC in ECU required

Working Principle : Faraday’s law of electro-magnetic induction

Facts and Figures

SOP : 01/2016 Mounting Location

On the turbo-charger


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Magnet

Coil


Air gap range up to 2 mm (blind hole)

Ambient temperature

at the sensor tip:

-40 °C ... +180 °C

(short term +200 °C)

Rotation speed

/ Signal band width

ca. 10 … 400·103 rpm

/ 2 kHz ... 70 kHz

Measurement principle Inductive passive

Sensing coil

Target wheel profile

Magnet


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Cam Position sensor PG-3.8 /-3.9 / CPS4

Features

Single Hall principle / single-track target wheel

True-Power-On

Twist insensitive mounting


Small sensor diameter 11.3 mm (PG-3.9)

Working Principle : Hall effect

Determines the position of the camshaft

Application

Facts and Figures

SOP : 2003

PG3.9

PG3.8

CPS4Mounting Location

Rear-end of the cam shaft


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Functional principle

Basics of Application.

target wheel

Magnetic induction B depending on wheel angle

angle of target wheel

electricaloutput-signal

0 45 90 135 180 225 270 315 360

slot

switching

threshold

toothB


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Throttle Position Sensor

Features

Angle sensor with linear functional characteristic (Potentiometer)

Throttle valve angle 0..86°

Minimum flange bore-to-bore distance 40 mm

Throttle shaft interface 8 mm with D-shaped cross-section

Supply voltage 5V

Temperature range -40°..+130°C

Working Principle : Potentiometer

Determines the position of the throttle valve

Application

Facts and Figures

SOP(India) : 2016 Mounting Location

On the throttle body


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Measure position of the throttle valve

TPS provides engine management system

with information regarding position of

throttle and therefore engine load - vital for

fuelling and ignition mapping for optimum

performance and efficiency


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Exhaust sensor portfolio DGS-ESProduct Area | Exhaust Sensors

Nitrogen Oxide

Sensors

(EGS-NX)

Particulate Matter

Sensors

(EGS-PM)

Temperature

Sensors

(EGS-T)

Oxygen

Sensors

(LS)


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Planar sensor element with thermo shock protection (TSP)

Fast light-off-time (< 12 s at 10,5 V)

Sensor readiness before due point end possible

Xfour typical advantages:

Compact design, pumped reference leads to improved resistance against

contamination, high peak-temperature robustness up to 1030°C (300h)

and permanent operating temperature 980°C

With Low temperature control (LTC):

Early signal availability at low sensor element temperature

Fast sensor readiness ≤ 10s after engine start

Working Principle : Nernst Principle + Ionization

Planar Switching Type Lambda Sensor - LSF Xfour TSP

Features

Application

Facts and Figures

SOP : 2012Mounting Location

On the exhaust tail pipe

Pre/Post catalyst

Measures the content of O2 in exhaust gas


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Sensing cell

HeaterReferenceair PO2

PO2

ZrO2-Ceramic

Electrodes

Porous protective layer

Insulation

PO2US

RT

4F= In

PO2

Sensor Characteristic Curve

Normalized A/F ratio

Se

nso

r vo

lta

ge

0 0.98 1.0 1.02

Ureg

0

0.3

0.6

0.9

V

Exhaust gas



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Facts and Figures

SOP : 2003


Fast sensor readiness after engine start due to Thermo-shock protection

(TSP) & Fast light-off (FLO ≤ 12s)

Lambda control for gasoline engines

Continuous signal & wide measurement range (0,70 – air)

Planar sensor element with integrated, central heater

Robust sensor element design through pumped reference

High peak-temperature robustness up to 1030°C (250h);

permanent operating temperature 930°C

Trim resistor in connector housing


Planar Wideband Lambda Sensor – LSU 4.9

Features

Application

Mounting Location


Pre/Post catalyst


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Facts and Figures

SOP : 2013


New sensor design (sensor element and protection tube) optimized for Diesel applications

Compact 4 wire sensor concept

Temperature requirements designed to suit diesel application

Enhanced soot robustness

Thermal shock protection (TSP)


Lambdasensor-Diesel (LSU 5.1)

Features

Application

LSU4.9 LS-Diesel

LS-Diesel (LSU5.1)

Mounting Location


Pre/Post catalyst


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Outer pump

electrode

Inner

pump-

electrode

Reference air electrodeHeater

Exhaust:

O2, CO,

H2, HC

Diffusion-

barrier

O2-

O2

2P O~ pI

Zircondioxide

IP-MeasureApply Voltage e-040812

measure chamber

state: target 450 mV


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Facts and Figures

SOP(PC) : 02/2015

SOP(CV) : [12 V] – 07/2016

[24 V] – 01/2017

EGS-NX 2nd Gen (Nitrogen Oxides)

Features

Application

SCU Digital output, CAN bus capable, enables for ...

Standardized protocol (e.g. SAE J1939) or customer-specific CAN

NOx and O2 signal

NH3 as an additional contribution to the NOx signal

125°C environmental temperature SCU, engine mounting of SCU possible

Specified for 6.000* h / 186.500 miles (300.000 km)

Additional pin for position detection / Sensor classified in QM system(ASIL)


Measures the content of NOx & O2 in exhaust gas

Mounting Location


Post catalyst


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Facts and Figures

SOP : 2014

EGS-PM sensor

Features

Application

OBD: DPF monitoring for US MY2013 and EU6 by direct measurement of particulate matter downstream DPF.

Sensor equipped with active electronics in separate SCU

Sensing principle: resistivity measurement of deposited soot;

sensor regeneration by periodic heating.

Ceramic sensing element with integrated heater, temperature

sensing element and inter-digital electrodes.

Communication with ECU: sensor with CAN interface.

Electrical interface: 12V supply(PC), 24V(CV).

Working Principle : Resistance measurement

Measures the amount of particulate matter from the exhaust

Mounting Location


Post catalyst


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(1) positioning of sensor in exhaust pipe

(3) protection tube guides partial gas stream over interdigital electrodes (IDE)

(5) Growth of conductive soot paths through continuous accumulation

(4) soot accumulation on and between interdigital electrodes (IDE)

(2) protection tube bleeds off partial gas stream from main stream in pipe

Sensorsubstrat

exhaust gas

electrode

electrode

Resistance between interdigital electrodes depends on soot adsorption

Periodic heating regenerates sensor surface by burning soot layer off


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Facts and Figures

SOP : end 2018

Pt200 sensor element

3 base variants for all automotive applications

Value: -40 °C up to 800°C

Performance: -40 °C up to 950°C

High-End: -40 °C up to 1150°C

Closed sensor housing

Flexible design

Very fast response time & high accuracy over lifetime

Very high thermal shock & thermal cycle robustness

Working Principle : PTC – Positive temperature coefficient

EGS-T | Exhaust Gas Temperature Sensor

Features

Application

Intrusion depth 25 – 80 mm

M12, M14

Wire harness length & connector

according customer specification (wire

harness length 200 mm – 1500 mm)

Customer specific wire harness fixation

Measures the temperature of the exhaust

Mounting Location


Inlet/Outlet of EGR

Before/after DPF

EGR – Exhaust Gas Re-circulation

DPF – Diesel Particulate Filter


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Thank you for your attention

Documents

Bosch Power-train / Exhaust Sensors Overview - IIT Kanpur · PDF file · 2016-09-07Bosch Power-train / Exhaust Sensors Overview ... Working Principle : Wheatstone Bridge(Pressure