Pressure sensors and systems - Measurement Systems and … · 2020-04-21 · Pressure sensors and systems. Innovative solutions for engine combustion analysis. . Plastics processing

www.kistler.com

Pressure sensors and systemsInnovative solutions for engine combustion analysis

www.kistler.com

Plastics processing Optimized process transparency for injection molding

Increased cost efficiency with cavity pressure- based systems

www.kistler.com

Measuring made easyMeasuring solutions with Kistler's DTI technology for vehicle and tire testing.

Digitizesynchronizeoptimize

100-

459e

-04.

15

©20

15, K

istle

r G

roup

R&D with Kistler solutions

www.kistler.com

Engine combustion analysisPressure sensors and innovative system solutions

www.kistler.com

Indicating powerKiBox – the flexible indicating system from Kistler

High-precision engine indicating – onboard and on the test bench

Kistler GroupEulachstrasse 228408 Winterthur SwitzerlandTel. +41 52 224 11 11

Kistler Group products are protected by various intellectual property rights. For more details, visit www.kistler.com. The Kistler Group includes Kistler Holding AG and all its subsidiaries in Europe, Asia, the Americas and Australia.

Find your local contact atwww.kistler.com

Find out more about our applications: www.kistler.com/applications

Sensor selection guide Piezoelectric sensors Piezoelectric sensors

Pressure measurement in combustion enginesCylinder pressure

Pressure measurement in the intake and exhaust systems General Purpose Presure Measurement PiezoSmart Automatic Sensor Identification

Piezoresistive sensors

Sensors, uncooled Sensors and measuring probes, cooled Measuring spark plugs Glow plug adapter Optical

Technical data Type 6054C Type 6052C Type 6054BRU20/U56 Type 6056A Type 6124A Type 6125C Type 6044A Type 6041B Type 6061C Type 6067D Type 7061C Type 6113C/6115C/6118C Type 6542 Type MMSP

Pressure range bar 0 ... 300 0 ... 250 (300) 0 ... 300 0 ... 250 (300) 0 ... 300 0 ... 300 0 ... 300 0 ... 250 0 ... 250 0 ... 250 0 ... 250 0 ... 250 for 6056A 0 ... 250

Sensitivity pC/bar -17 -20 (-18) -13 (-9*) -20 (-19) -30 -36 (33) -30 -40 -25 -25 -92 -10 -10

Linearity % <± 0,3 <± 0,3 (<± 0,5) <± 0,3 (<± 0,5) <± 0,3 <± 0,3 <± 0,4 <± 0,3 <± 0,3 <± 0,5 <± 0,3 <± 0,3 <± 0,5 <± 0,5

Temperature range °C -20 ... 350 -20 ... 350 -20 ... 350 -20 ... 350 -20 ... 350 -20 ... 350 -20 ... 350 -20 ... 350 -20 ... 350 -20 ... 350 -20 ... 350 -20 ... 200 -20 ... 200

Dimensions T M5x0.5 M5x0.5 M5x0.5 M5x0.5 6.2mm pluggable 6.2mm pluggable M8x0.75 M8x0.75 M10x1 9.9 mm pluggable M14x1.25 M10x1/M12x1.25/M14x1.25 M10x1/M12x1.25/M14x1.25

Characteristics • New compact M5 sensor• High accuracy and

durability in one sensor• Excellent strain

interference rejection• Multi-applications sensor

for the whole engine development process

• Low cost of ownership thanks to long service life

• High performance, with or without flameguard

• Compact higly accurate sensor

• Low thermal sensitivity shift over the whole engine operating map, compensated for acceleration

• Ideal thermal shock behavior

(reinforced version in brackets)

• Very compact, rugged design for high performance measurements even in limited space applications, insensitive to vibrations and structure borne noise


• Sensor properties as Type 6052C...

• application in glow plug adaptors 6542Q and mounting sleeves


• New generation measuring element

• Insensitive to installation strain

• Pluggable sensor with swivel-nut for easy handling

• Ideal for direct mounting• Rugged• Very small linearity error• Minimal sensitivity change

over whole temperature range

• As 6124A with ground insulation


• New generation measuring element

• Insensitive to installation strain

• Ideal for direct mounting• Rugged and consistent• Very small linearity error• Minimal sensitivity

shift over the whole temperature range

• Smallest water cooled cylinder pressure sensor

• Excellent thermal sensitivity and drift stability

• Water cooled pressure sensor, excellent thermal drift stability

• Sensor properties as Type 6061C...

• Pluggable sensor, easy to install and remove

• Water cooled pressure sensor

• Best thermal shock behavior and excellent thermal drift stability

• Ideal as a reference sensor

• Measuring spark plug sensor flush mounted with high natural frequency

• Highly durable ceramic adaptation with improved flash-over resistance

• Various heat ranges and geometries available

• Ceramic insulator, cable and sensor replaceable

• Glow plug adapter enables cylinder pressure measurement without separate measuring bore

• Design corresponding to existing glow plug bore

• High signal quality• Standard sensor for

different glow plug geometries

• With tip or tipless design

• Multi measuring spark plug with integrated high temperature miniature pressure sensor and fiber optic system

• For pressure indication and optical combustion analysis in gasoline engines

Data sheet 003-458 000-552 003-046 000-529 003-268 000-695 003-399 000-516 003-454 003-467 003-042 003-281/003-269/003-280 000-570 003-428

Low-pressure sensors DigitalSmart (DS series) High-pressure sensors DigitalSmart (DS series) Pressure/Temperature transmitter

Technical data Type 4007D Type 4011A Type 4049B... Type 7533B Type 4065B... Type 4067E... Type 4080B/4080BT Type 4260A/4262A/4264A

Pressure range bar 0...5/10/20/50/100/250 0…5/ 10/20/50/100/ 250/500

0...5/10 for sensor type 4011A, 4045, 4075

0...200/500/1000 0 ... 2 000/3 000 0 ... 5/10/20/130/250 0...5/10/20

Temperature range °C 25 … 180 -20 ...120 (L),15 ...180 (H) 0 … 80 25 ... 120 25 ... 180 25 … 150 25 … 150

Dimensions M5x0.5 M5x0.5/M8x0.75M12x1/M14x1.25

M14x1.25 M14x1.25 M7x0,75 M10x1 M6x1 M6x1

Characteristics • Miniature pressure sensor for intake pressure measurements

• Ideal for applications with limited space

• Universal pressure sensor• Highest accuracy• Media separated• Versatile adaptable, with

M5, M6 or M8 media connection; or type 4073/4075, 4043/4045 compatible

• Compact pressure sensor with integrated water cooling for exhaust gas pressure measurements

• Media separated

• Cooling adapter with pneumatic switching function allowes zero point correction for gas exchange sensors while combustion engine is running

• For highest accuracy measurements

• Compact high-pressure sensor

• Robust steel diaphragm for harsh and high dynamic applications

• High-pressure sensor front sealing

• Robust steel diaphragm for harsh and high dynamic applications

• Robust, media separated miniature pressure transmitter

• With integrated signal conditioning

• Ideal for on-board applica-tions and applications with limited space

• 4080BT includes media temperature sensor with signal conditioning; <20bar

• Robust, media separated pressure transmitter

• Electrical output options mV, V and mA

• Wide choice of pressure & electrical connection

• Hazardous area certification ATEX (optional)

Application • Intake pressure• General pressure

• Intake/exhaust pressure• General pressure

• Exhaust pressure • Intake/Exhaust pressure • Injection pressure • Injection pressure • Motorsport• General pressure

• General pressure

Data sheet 003-300 003-267 003-145 002-614 003-165 003-166 003-391 003-193/003-388/003-192

Possibility of engine modification

Yes

No Gasoline

General purpose

Thermodynamic

Knock detection

Spark plug

Type 6054C

Type 6054C/6052C

Type 6054BRU20/U56

Type 6113C/6115C


Yes

No Gasoline

Diesel

General purpose

Thermodynamic

Knock detection

Spark plug

Glow plug Type 6542Q

Type 6124A/6044A/6054C

Type 6041B/6044A/6054C

Type 6054BRU20/U56

Type 6113C/6115C/6118C

Type 6056A

General purpose

Thermodynamic

Type 6124A/6044A/6054C

Type 6061C/6067D

Type 6041B/6044A/6054C

General purpose

Knock detection/On-board

Type 6054BRU20

Type 6054BRU56

Small sized engines(motorbikes, ...)

Medium sized engines(passenger cars, ...)

Heavy duty engines(trucks, ...)

Racing engines

Intake/Exhaust/Hydraulic pressure

Compact solution

Intake/un-cooled

Exhaust/cooled

Type 4007D

Type 4049B

Highest accuracy

Intake/exhaust switching adapter water cooled Type 7533B

Type 4011A

Transmitter/On-board

without media temperature

with media temperature

Type 4080B

Type 4080BT

Injection/High pressure

Sensor

Clamping adapter Type 6533

≤ 1 000 bar

≤ 3 000 / 3 600 bar*

Type 4065B

Type 4067E

For absolute pressure sensors For cylinder pressure sensors: Recording of operating time, cycles and classification of pressure values

PiezoSmart is an active system for identifying individual piezoelectric pressure sensors. The main element of PiezoSmart is an electronic data sheet called TEDS (TEDS = Transducer Electronic Data Sheet). It contains all essential data of an individual pressure sensor and can exchange these with ancillary equipment.

All piezoelectric and piezoresistive pressure sensors from Kistler are available with PiezoSmart.

Charge or voltage amplifiers automatically set the correct parameters by exchanging data with the TEDS of the pressure sensor.

• Correct assignment of the sensor data is always guaranteed. You benefit from enhanced process reliability

• Measurement can take place independently without any database

• Automatic recording of operating time and cycles of PiezoSmart pressure sensors with classification of pMax value

PiezoSmart is an active system for identifying individual piezoresistive pressure sensors. The main element of PiezoSmart is an electronic data sheet called TEDS (TEDS = Transducer Electronic Data Sheet).It is integrated in the Fischer connector and contains serial number, sensor type, calibration model and data.Plug and play with Kistler amplifiers 4624A/4665B

Type 4785A...: universal extension cable forDS Sensor series in various lengths

* only common rail application = Dimensions n = Type

Database

Sensor Seal Connecting cable PiezoSmart® coupling

pMax range recorded cycles

Information is stored on TEDS

TEDS template with

working time for

a piezoelectric

pressure sensor

Automatic recording of

operating time of PiezoSmart

pressure sensors with

classification of pMax values

SCP charge amplifier Type 5064D...

Sensor selection guide Piezoelectric sensors Piezoelectric sensors

Pressure measurement in combustion enginesCylinder pressure

Pressure measurement in the intake and exhaust systems General Purpose Presure Measurement PiezoSmart Automatic Sensor Identification

Piezoresistive sensors

Sensors, uncooled Sensors and measuring probes, cooled Measuring spark plugs Glow plug adapter Optical

Technical data Type 6054C Type 6052C Type 6054BRU20/U56 Type 6056A Type 6124A Type 6125C Type 6044A Type 6041B Type 6061C Type 6067D Type 7061C Type 6113C/6115C/6118C Type 6542 Type MMSP

Pressure range bar 0 ... 300 0 ... 250 (300) 0 ... 300 0 ... 250 (300) 0 ... 300 0 ... 300 0 ... 300 0 ... 250 0 ... 250 0 ... 250 0 ... 250 0 ... 250 for 6056A 0 ... 250

Sensitivity pC/bar -17 -20 (-18) -13 (-9*) -20 (-19) -30 -36 (33) -30 -40 -25 -25 -92 -10 -10

Linearity % <± 0,3 <± 0,3 (<± 0,5) <± 0,3 (<± 0,5) <± 0,3 <± 0,3 <± 0,4 <± 0,3 <± 0,3 <± 0,5 <± 0,3 <± 0,3 <± 0,5 <± 0,5

Temperature range °C -20 ... 350 -20 ... 350 -20 ... 350 -20 ... 350 -20 ... 350 -20 ... 350 -20 ... 350 -20 ... 350 -20 ... 350 -20 ... 350 -20 ... 350 -20 ... 200 -20 ... 200

Dimensions T M5x0.5 M5x0.5 M5x0.5 M5x0.5 6.2mm pluggable 6.2mm pluggable M8x0.75 M8x0.75 M10x1 9.9 mm pluggable M14x1.25 M10x1/M12x1.25/M14x1.25 M10x1/M12x1.25/M14x1.25

Characteristics • New compact M5 sensor• High accuracy and

durability in one sensor• Excellent strain

interference rejection• Multi-applications sensor

for the whole enginedevelopment process

• Low cost of ownershipthanks to long service life

• High performance, withor without flameguard

• Compact higly accuratesensor

• Low thermal sensitivityshift over the wholeengine operatingmap, compensated foracceleration

• Ideal thermal shockbehavior


• Very compact,rugged design forhigh performancemeasurements even inlimited space applications,insensitive to vibrationsand structure borne noise


• Sensor properties asType 6052C...

• application in glow plugadaptors 6542Q andmounting sleeves


• New generationmeasuring element

• Insensitive to installationstrain

• Pluggable sensor withswivel-nut for easy handling

• Ideal for direct mounting• Rugged• Very small linearity error• Minimal sensitivity change

over whole temperaturerange

• As 6124A with groundinsulation


• New generationmeasuring element

• Insensitive to installationstrain

• Ideal for direct mounting• Rugged and consistent• Very small linearity error• Minimal sensitivity

shift over the wholetemperature range

• Smallest water cooledcylinder pressure sensor

• Excellent thermal sensitivityand drift stability

• Water cooled pressuresensor, excellentthermal drift stability

• Sensor properties asType 6061C...

• Pluggable sensor, easy toinstall and remove

• Water cooled pressuresensor

• Best thermal shockbehavior and excellentthermal drift stability

• Ideal as a reference sensor

• Measuring spark plugsensor flush mountedwith high naturalfrequency

• Highly durable ceramicadaptation with improvedflash-over resistance

• Various heat ranges andgeometries available

• Ceramic insulator, cableand sensor replaceable

• Glow plug adapterenables cylinder pressuremeasurement withoutseparate measuring bore

• Design corresponding toexisting glow plug bore

• High signal quality• Standard sensor for

different glow pluggeometries

• With tip or tipless design

• Multi measuring sparkplug with integrated hightemperature miniaturepressure sensor and fiberoptic system

• For pressure indicationand optical combustionanalysis in gasolineengines

Data sheet 003-458 000-552 003-046 000-529 003-268 000-695 003-399 000-516 003-454 003-467 003-042 003-281/003-269/003-280 000-570 003-428

Low-pressure sensors DigitalSmart (DS series) High-pressure sensors DigitalSmart (DS series) Pressure/Temperature transmitter

Technical data Type 4007D Type 4011A Type 4049B... Type 7533B Type 4065B... Type 4067E... Type 4080B/4080BT Type 4260A/4262A/4264A

Pressure range bar 0...5/10/20/50/100/250 0…5/ 10/20/50/100/ 250/500

0...5/10 for sensor type 4011A, 4045, 4075

0...200/500/1000 0 ... 2 000/3 000 0 ... 5/10/20/130/250 0...5/10/20

Temperature range °C 25 … 180 -20 ...120 (L),15 ...180 (H) 0 … 80 25 ... 120 25 ... 180 25 … 150 25 … 150

Dimensions M5x0.5 M5x0.5/M8x0.75M12x1/M14x1.25

M14x1.25 M14x1.25 M7x0,75 M10x1 M6x1 M6x1

Characteristics • Miniature pressuresensor for intake pressuremeasurements

• Ideal for applications withlimited space

• Universal pressure sensor• Highest accuracy• Media separated• Versatile adaptable, with

M5, M6 or M8 mediaconnection;or type 4073/4075,4043/4045 compatible

• Compact pressure sensorwith integrated watercooling for exhaust gaspressure measurements

• Media separated

• Cooling adapter withpneumatic switchingfunction allowes zeropoint correction for gasexchange sensors whilecombustion engine isrunning

• For highest accuracymeasurements

• Compact high-pressuresensor

• Robust steel diaphragmfor harsh and highdynamic applications

• High-pressure sensorfront sealing

• Robust steel diaphragmfor harsh and highdynamic applications

• Robust, media separatedminiature pressuretransmitter

• With integrated signalconditioning

• Ideal for on-board applica-tions and applications withlimited space

• 4080BT includes mediatemperature sensor withsignal conditioning; <20bar

• Robust, media separatedpressure transmitter

• Electrical output optionsmV, V and mA

• Wide choice of pressure &electrical connection

• Hazardous areacertification ATEX(optional)

Application • Intake pressure• General pressure

• Intake/exhaust pressure• General pressure

• Exhaust pressure • Intake/Exhaust pressure • Injection pressure • Injection pressure • Motorsport• General pressure

• General pressure

Data sheet 003-300 003-267 003-145 002-614 003-165 003-166 003-391 003-193/003-388/003-192


Yes

No Gasoline

General purpose

Thermodynamic

Knock detection

Spark plug

Type 6054C

Type 6054C/6052C

Type 6054BRU20/U56

Type 6113C/6115C


Yes

No Gasoline

Diesel

General purpose

Thermodynamic

Knock detection

Spark plug

Glow plug Type 6542Q

Type 6124A/6044A/6054C

Type 6041B/6044A/6054C

Type 6054BRU20/U56

Type 6113C/6115C/6118C

Type 6056A

General purpose

Thermodynamic

Type 6124A/6044A/6054C

Type 6061C/6067D

Type 6041B/6044A/6054C

General purpose

Knock detection/On-board

Type 6054BRU20

Type 6054BRU56

Small sized engines(motorbikes, ...)

Medium sized engines(passenger cars, ...)

Heavy duty engines(trucks, ...)

Racing engines

Intake/Exhaust/Hydraulic pressure

Compact solution

Intake/un-cooled

Exhaust/cooled

Type 4007D

Type 4049B

Highest accuracy

Intake/exhaust switching adapter water cooled Type 7533B

Type 4011A

Transmitter/On-board

without media temperature

with media temperature

Type 4080B

Type 4080BT

Injection/High pressure

Sensor

Clamping adapter Type 6533

≤ 1 000 bar

≤ 3 000 / 3 600 bar*

Type 4065B

Type 4067E

For absolute pressure sensors For cylinder pressure sensors: Recording of operating time, cycles and classification of pressure values

PiezoSmart is an active system for identifying individual piezoelectric pressure sensors. The main element of PiezoSmart is an electronic data sheet called TEDS (TEDS = Transducer Electronic Data Sheet). It contains all essential data of an individual pressure sensor and can exchange these with ancillary equipment.

All piezoelectric and piezoresistive pressure sensors from Kistler are available with PiezoSmart.

Charge or voltage amplifiers automatically set the correct parameters by exchanging data with the TEDS of the pressure sensor.

• Correct assignment of the sensor datais always guaranteed. You benefit fromenhanced process reliability

• Measurement can take place independentlywithout any database

• Automatic recording of operating time andcycles of PiezoSmart pressure sensors withclassification of pMax value

PiezoSmart is an active system for identifying individual piezoresistive pressure sensors. The main element of PiezoSmart is an electronic data sheet called TEDS (TEDS = Transducer Electronic Data Sheet).It is integrated in the Fischer connector and contains serial number, sensor type, calibration model and data.Plug and play with Kistler amplifiers 4624A/4665B

Type 4785A...: universal extension cable forDS Sensor series in various lengths

* only common rail application = Dimensions n = Type

Database

Sensor Seal Connecting cable PiezoSmart® coupling

pMax range recorded cycles

Information is stored on TEDS

TEDS template with

working time for

a piezoelectric

pressure sensor

Automatic recording of

operating time of PiezoSmart

pressure sensors with

classification of pMax values

SCP charge amplifier Type 5064D...

Multichannel Singlechannel

Signal conditioningSignal conditioning platforms and amplifier modules Amplifier

Combustion analysis Accessories

KiBox

Combustion Analysis System

Chargeamplifier

5064D11/C12*/13*

003-047

Piezoresistive

amplifier

4665B1* 000-724

Crank angle

adapter

2619A 000-724

Crank angle

encoder

2614C 003-049

Current clamp 2105A 000-953

TDC SensorSystem

2629DK 003-334

* with PiezoSmart function

Technical data Type 2893B

Analog inputs for any voltage signals

channels 8/16*

Digital inputs channels 8/16*

Input voltage range V -10 … 10

ADC resolution Bit 16

ADC sampling rate (per channel, MS/s)

MHz 1.25

Space for integrated amplifier modules

– max. 4/8*

Low-pass filter kHz 5/10/20/25/30/35/40

Min./Max. temperature °C -30/50

Weight kg 8 (1 KiBox, amplifiers included)

Dimensions (WxHxD) mm 265,5x212x440

Key features • up to 16 channels, 4 current clamps, digital IO• KID3 Bosch knock intensity detections• User Formulas in real time• Latest generation signal processor & performance• XCP universal interface• ETAS INCA, ATI Vision, Vector CANape compatible

Characteristics The KiBox is a complete combustion analysis system for on-board and test-bed applications. It enables the visu-alization of the quality of combustion. The combustion parameters are conveniently integrated into the ECU calibration system, test bench system and synchronized with other measurement data.

Data sheet 000-724

* cascaded KiBox

1) Sensor temperature measurement 2) Thermocouple temperature measurement

Signal conditioning platform

2852B... 2853B...

Module

Application

Type 5064D 4665B 5247 5269 5271 2207A 4624A 5018A

Cylinder pressure (piezoelectric) n n

Fuel pressure (piezoresistive) n n

Intake pressure (piezoresistive) n n

Exhaust pressure (piezoresistive) n n

pMax monitoring n n

Needle lift measurement n

Temperature measurement n 1) n 2) n 1)

Voltage measurement n

Strain gage measurement n

Sensor identification n n n n

Recording of cycles and working time n n

Connecting

Connecting and extension cables

For piezo electric connecting cables

Triboelectrically optimized cables

Adapters

M3 pos. M4 pos. 10-32 pos. BNC pos. BNC neg. TRIAX neg.

1989A3_1 (2)1989A7_1 (4)

M3 pos.

1989A1_3 (1)1989A3_3 (2)1989A7_3 (4)

1929A_ (2)1983AA_ (4)

M4 pos.

1975A_ (2)1983AB_ (4)

1967A_ (2)*1969A_ (2)1983AC_ (4) 10-32 pos.

1601B_ (5) 1603B_ (5)

BNC pos.

1985A8S3_1 (2)1985A8S7_1 (4)

1985A1S3_1 (2)1985A1S7_1 (4)

1985A2S3_1 (2)1985A2S7_1 (4)

1987B_ (3)Triax pos.

(PiezoSmart)

1987BFT_ (3)Fischer Triax(PiezoSmart)

M4 neg. 10-32 neg. 10-32 pos. BNC pos. TRIAX neg.

1700A35 1706

M3 neg.

1700A23 1700A13 1700A31 1705 1704A3

M4 neg.

1729A 1721 1704A2

10-32 neg.

1704A1

BNC neg.

1704A4

TRIAX pos.

(1) PFA Coax cable, green (-90 up to +200°C): The characteristics of the perfluoro alkoxy alkane (PFA) cable braidings include its strength, even at very high temperatures, as well as excellent thermal stability and superb chemical resistance.

(2) PFA Coax cable, steel braided (-55 up to +200°C): To protect the cable against mechanical damage, it is equiped with a flexible stainless steel braiding. In other respects its design corresponds to the PFA/green version. * with ground insulation

(3) FPM Triax cable, black (-20 up to +200°C): The Fluoropolymer (FPM) material is characterized by high thermal and chemical resistance, particularly to hydrocarbons.(4) FPM Coax cable, oilproof IP68, black (-20 up to +200°C): The Fluoropolymer (FPM) material is characterized by high thermal and chemical resistance, particularly to hydrocarbons. The cable is equiped with a liquid-tight connector, which makes it robust and resistant against oils and fuels.(5) PVC Coax cable, black (-25 up to +85°C)

www.kistler.com



www.kistler.com



100-

459e

-04.

15

©20

15, K

istle

r G

roup


www.kistler.com

Engine combustion analysis Pressure sensors and innovative system solutions

www.kistler.com







Triboelectrically optimized cables

M4 neg. 10-32 neg. 10-32 pos. BNC pos. TRIAX neg.

1700A35 1706

M3 neg.

1700A23 1700A13 1700A31 1705 1704A3

M4 neg.

1729A 1721 1704A2

10-32 neg.

1704A1

BNC neg.

1704A4

TRIAX pos.

www.kistler.com



www.kistler.com



100-

459e

-04.

15

©20

15, K

istle

r G

roup


www.kistler.com

Engine combustion analysis Pressure sensors and innovative system solutions

www.kistler.com







961-

310e

-06.

19

©20

19, K

istle

r G

roup

Documents

Pressure sensors and systems - Measurement Systems and … · 2020-04-21 · Pressure sensors and systems. Innovative solutions for engine combustion analysis. . Plastics processing