Transcript
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Automotive Sensors & ActuatorsAutomotive Sensors & ActuatorsAutomotive Sensors & ActuatorsAutomotive Sensors & Actuators
Lecture delivered by:Lecture delivered by:
M.S Ramaiah School of Advanced Studies - Bangalore 1
Prof.Prof. Ashok C.MetiAshok C.Meti
MSRSASMSRSAS--BangaloreBangalore
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Session Objectives
On completion of this session the delegates
would have understood :
e var ous sensors an actuators t at are use
in automotive electronics,
Their working principles,
Their various uses in automotive electronic
systems
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Topics
Introduction to automotive electronics Automotive sensors and actuators
Selection criterion
Different types of sensors
Actuators
A case study Honda City car
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Over the past 30 years, vehicle electronic systems have
changed significantly.
Automotive Electronics - Introduction
electronic systems.
The evolution of microcontroller and sensor technology is
allowing automobile industry to create complex systems
that can provide higher levels of vehicle control and safety.
The overall oal of electronic embedded s stem desi n is
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to balance production costs with development time and
cost.
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Automotive Sensors & Actuators
Automotive manufacturers are continuously increasingcontinuously increasing
the use of electronics systems to-
Safety
passenger comfort.
SensorsSensors and actuatorsactuators integrated with automotive control
computers help optimize vehicle performance while
im rovin reliabilit and durabilit .
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SensorSensor-- InputInput ActuatorActuator-- OutputOutputMicrocontrollerMicrocontroller
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Measurement System
CPUA/DSIGNALCONDITIONING
SENSOR
VOLTAGE SERIAL
OR
PARALLEL
ELECTRICAL
OUTPUTMEASURED
QUANTITY
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Selection Criteria What is to be measured
Magnitude, range, dynamicsof measured quantity
Required resolution, accuracy
Cost
Environment
Interface Requirements: Output quantity (voltage,
current, resistance,)
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Signal conditioning
A/D requirements (#bits, datarate)
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Thermistors
Commonly used for temperature measurementon vehicles.
They are made out of semiconductor materials
such as cobalt or nickel oxides.
Change in temperature causes change inchange in
resistanceresistance of the thermistor.
Most of the thermistors are of the negativenegative
temperature coefficienttemperature coefficient (NTC) type
o
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to a few hundred Ohmshundred Ohms at 100o C. Thus it can
be more sensitive.
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Important factors for accuratemeasurements: Supply must be constant
Current through the thermistorshould be negligible ( I.e. No heatingeffect)
These devices are commonly used assensors for-
Air intake
Battery
Engine and transmission temperature
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Air conditioning and internal/externalenvironmental temperature
Oil and gas temperatures.
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Temperature sensor
Application Engine management
Function Registration of temperature ofcoo ants, ue an a r
Installation Engine block, coolantcircuit, air-intake tract
Sensing principle NTC technology (hotconductor, negative temperaturecoefficient)
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Temperature range: -40C...+150C
Time constant: 5 s...44 s (depending on type) Accuracy: 0.8 K at 100C 1.5 K at 20C
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Thermocouples When two dissimilar metalstwo dissimilar metals are joined together, thethermocouple junction is formed.
Among the two junctions used, one of the junctions is kept
a a cons an nown empera ure w ere as e o er a e
temperature to be measured.
Ex: 70% platinum & 30% rhodium alloy known as B Type
, Has a range of 0 15000C.
Used for measuring Exhaust GasExhaust Gas and turbochargerturbocharger
temperaturestemperatures in a vehicle.
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Magnetic Sensors
Variable Reluctance (VR) SensorsVariable Reluctance (VR) Sensors
Used mainly for speed and position
measurements of rotating members. ( Ex:crank shaft speed and position sensing)
The variable reluctance sensor is an electro-
magnetic device consisting of a permanentpermanent
magnetmagnet surrounded by a winding of wirewinding of wire.
The sensor is used in conjunction with a
ferrous target that either has notches or teeth.
Rotation of the target wheeltarget wheel near the tip of the
sensor chan eschan es the ma netic fluxma netic flux, creatin an
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analog voltage signal in the sensor coil.
Though the voltage may vary depending on the
speed of rotating member, the frequencyfrequency is
used for measurement.
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A common method of
converting this signal into a
useful signaluseful signal for interfacinginterfacing
w o er g a c rcu s y
using a Schmitt triggerSchmitt trigger circuit.
Another method is by using a
quenched oscillator circuit as
shown in the figure. This circuit
has good resistance to
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.
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Typical Applications:
Ignition system engine speedand position
Speed sensing for
e ectron ca y contro e
transmissions
Vehicle speed sensing
Wheel speed sensing for ABS
and traction control systems
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Hall Effect Transducers
Principle:
If a certain type of crystal is carrying acurrent in a transverse magnetic field,then a voltage will be produced at right
.
The magnitude of the voltagemagnitude of the voltage isproportional to the supply currentsupply current and tothe magnetic field strength.
With proper designproper design, the output of thisdevice is a square wave.
The principle is used in distributors andalso to detect the current flowing on a
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ca e.
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Variable resistance
These sensors are mainly used for sensing larger changelarger change inpositionposition.
Example: The throttle position sensor, which is a
potentiometer.
It is supplied with a stablestable 5 Volts DC.
The wiper wiper is driven by the throttle shaftthrottle shaft. Thus , the voltage from
the wiper contact will be proportionalproportional to the throttle positionthrottle position.
In many cases,throttle potentiometer is used to indicate the raterate
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.
implementing acceleration enrichment or over-run fuel cut-off.
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Available in clockwise and anti-clockwise
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Printed Circuit Resistors
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Accelerator-pedal module
Application Engine management
Function Registering the driver's wisheseman or torque)
Installation Passenger compartment
Sensing principle Hall effect orpotentiometer
Technical data Supply voltage: 5 V
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easur ng range: cus omer-spec c pe a rave40 mm ... 80 mm
Temperature range: -40... +80C Output signal: analog
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Pressure sensor Application Engine management
Function Barometric pressure
Installation Printed circuit board(PCB)
Sensing principle Siliconmicromechanics with integratedevaluation circuit
Technical data
Measurin ran e: 60 kP
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...115 kPa
Analog output: 2.37 V ...4.54 V
Temperature range: -40C ... +130C
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Low-pressure sensors for gaseous media
Application Engine management
Function Registration of intake-manifold
ressure or atmos heric ressure
Installation Air-intake tract
Sensing principle Micromechanics with piezo-
resistive sensor element (MEMS based)
Technical data
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upp y vo age:
Power consumption: 9 mA (typical)
Measuring range: < 400 kPa (absolute) Response time: < 1 ms
Temperature range: -40... +130C
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Acclerometers Piezoelectric accelerometers are generally used as knockknock
sensors.sensors.
A piezoelectric accelerometer is a seismic mass
accelerometer using a piezoelectric crystalpiezoelectric crystal to convert the
forceforce on the mass due to acceleration into an electricalelectrical
output signaloutput 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
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knock a few degrees before and after the TDC.a few degrees before and after the TDC.
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The signals from this type of
sensors are detected by charge
amplifiers.
The sensitivity of a vehicle
knock sensor is about 20mV/g (
g=9.81 m/s2).
MEMS accelerometers are
replacing conventional
accelerometers for
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Knock sensing
Crash sensing
INS, etc
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Knock sensor
Application Engine management
Function Registration of structure-borne vibrations(knocking). Knocking combustion can damage the engine.The data from the knock sensor enables counter-measuresto be undertaken.
Installation Engine block
Sensing principle Piezo-electrical
Technical data
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Sensitivity at 5 kHz: 30 6 mV/g Linearity at 5-kHz value: 10 %
Frequency range: 3 kHz ...22 kHz
Temperature range: -40...+150C
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Application ESP
ABS
Safety (airbag systems)
the X, Y and Z axes
Installation Integration into circuit board (SMD)
Remote sensor
Sensing principle Surface mechanics(capacitive)
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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
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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:
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Air Flow Sensor
Air flow Sensor is another
example of variablevariable
resistanceresistance sensor.
When air flows in to the
sensor, exerts a forceforce on the
flapflap which is counteracted by
a calibrated springcalibrated spring. This
ensures that movement of the
flap is proportional to the
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through the sensor.
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A slider potentiometer is connected to the flap shaft.
The resistive material used for the track is a ceramic metal
mixture which is burnt into a ceramic plate at a very high
temperature.
The potentiometer is calibrated such that the output voltageoutput voltage
is proportional to the quantity of induced air.quantity of induced air.
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Hot wire air flow sensor
This measures air mass flowair mass flow. The basic principle is that as air passesair passes over a hot wirehot wire it
tries to cool the wire down. A circuit is created that tends
to increaseincrease the current through the wirecurrent through the wire. This current will
be proportionalproportional to the air flow.
The hot-wire:
Material - Platinum
Few mm long
Dia about 70 microns.
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Time constant very short (Small size)
Current range 0.5 to 1.2 A
Dirt problem Burn-off cycle at power-on or power-off.
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By-pass hot wire air flow meter
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Oxygen Sensor
The oxygen sensor provides a closed loopclosed loopfeedbackfeedback for the engine management
system to control the air fuel ratioair fuel ratio.i
The amount of oxygenamount of oxygen sensed is directly
related to the mixture strengthmixture strength or air-fuel
ratio.
Normalized air-fuel ratio() = Current air-
fuel ratio/Stoichiometric air-fuel ratio
i
Sensor 1 Air/Fuel Ratio
Sensor 2 Catalytic Converter Efficiency
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- .
known as a Lambda (Lambda () value of one) value of one.
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The sensor operates reliably above 300above 30000CC.
The EGO Exhaust Gas Oxygen sensors are
heating.
In some cases, a heating elementheating element is used to bring
the temperature to the working level quickly.
These heating element do not operatedo not operate all the time.0
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These are called HEGOHEGO.
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The main active component in most ofthe sensors is Zirconium dioxideZirconium dioxide, ZrO2
This ceramic material is housed in gasgas.
At temperatures above 3000C, thezirconium dioxide will conduct negativenegativeoxygen ionsoxygen ions.
The sensor is designed to be responsiveresponsivevery close to a Lambda value of 1.very close to a Lambda value of 1.
Greater quantity of oxygen ions will be
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is exposed to reference atmospheric air.
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Through electrolytic action these ions permeate the electrode and
migrate through the electrolyte. This builds up the chargecharge.
The magnitude of the charge is dependent on the oxygen % in the
exhaust.
A voltage of 400mV is the normal value at lambda value of onelambda value of one.
Most lambda sensors will cycle from rich to lean in about 50 to 100
milliseconds, and from lean to rich in 75 to 150 milliseconds. This is
referred to as the "transition" time. If the O2 sensor is taking
significantly longer to reverse readings, this too is an indication that it
is getting sluggish and may need to be replaced.
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Actuator is a general term to describe a control mechanism. An actuator is part of an openopen--looploop or closedclosed--loop controlloop control
systemsystem which connects the electronic unitelectronic unit with the process.process.
Actuators
The actuator consists of a transformer and a final-control
element.
Each positioning signals are converted to mechanical output.
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A wide variety of actuators are used in control
loops in an automobile
Solenoids
DC Motors
Stepper motors
Piezo Actuators and so on..
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Solenoid Actuators A solenoid is defined as a coil of wire commonly in the
form of a long cylinder that when carrying a currentresembles a bar magnet so that a moveable core
(armature) is drawn into (pulleddrawn into (pulled--in)in) the coil when a
curren owscurren ows.
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 compressescompresses a
spring.
On power-off, the armature returns back to its normal
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pos t on.
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
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Important considerations when designing a
solenoid for an application:
Force or Torque
Voltage
Current / Power
Duty Cycle
Temperature
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Operating Time / Speed
Environmental
AC / DC
Life
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One of the examples of solenoid actuatoris the one used in Fuel injectorFuel injector.
A typical fuel injector solenoid has theo ow ng: Stroke: 0.1mm
Open period range: 1.5 to 10.0 ms.
Coil resistance : 16
Time taken by an injector to open andclose is critical in fuel injection.
The induction of the coil la s an
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important role in the reaction time for thesolenoid. (Higher inductance -> longer reaction time,
ballast resistors)
Another application of solenoid actuatoris for door locksdoor locks.
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RelaysElectromagnetic switches
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DC Motors
Permanent magnet motors are commonly used inautomobiles as they are versatile.
The rotary speed (RPM) of the motor which is usually high is
su ta y mo e t roug gear ng owngear ng own ncrease n torque or
other mechanisms to get the desired rotaryrotary or linearlinear motion.
For applications such as power electric steering, the
options available are :
Brushless DC (BLDC)
Switched-reluctance motors (SRM)
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high temperature complications (automotive temperatures -40 to
125C.)
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Typical Specifications of a DC
Motor:
Voltage: 12V DC
10%
No load current:4A
Load: 7650r/min 10%,
0.226Nm, 19A
Rotation direction:
clockwise
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Some of the automotive applications: Windscreen and head light washers & wipers.
Power windows and mirrors.
Fuel pumps
Head light lifts.
Electronic Parking Brake (EPB)
Ventilation fans and so on..
One of the draw backs of a DC motor is non-availability of
direct feedbackdirect feedback. If required, one has to use variable
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res stor sensor to get t e necessary ee ac .
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Ex:
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Windows Motors
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Cable Window Lift Systems
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Actuators for cl imate control
Systems
EPB Actuator
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Actuators for Locking Systems
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Stepper Motors
Stepping motors: Permanent magnetType
Permanent magnet motors
usua y ave wo
independent windings, with
or without center taps.
Center-tapped windings are
used in unipolar permanent
magnet motors.
Variable reluctance Type
Variable reluctance motors
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usually have three
(sometimes four or five)
windings, with a commonreturn.
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Angular resolution:
The coarsest motors typically turn 90 degrees perstep
High resolution permanent magnet motors arecommonly able to handle 1.8 or even 0.72degrees per step.
an appropr a e con ro er, mos permanenmagnet and hybrid motors can be run in half-steps, and some controllers can handle smallerfractional steps or microsteps.
For both permanent magnet and variablereluctance stepping motors, if just oneonewindingwinding of the motor is energized, the rotor
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and then holdhold that angle until the torqueexceeds the holding torqueholding torque of the motor, atwhich point, the rotor will turn, trying tohold at each successive equilibrium point.
They do not have high starting torquestarting torque.
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Applications: Idle speed air by-pass
Speedometer display drives
Adaptive Front-lighting
(AFS) system, etc. Digital Instrument ClusterAdaptive Front-lighting System
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Piezo Actuators A piezo actuator enables response times of just a
few Tenth of a millisecond.
It consists of many crystal layers that expand bya few hundredths of millimeters when volta e isapplied.
One of the automotive applications of the Piezoactuators is in Diesel Unit Injection Systems.
Example:
Stacked actuator
Motion up to 100 m
Maximum load 3500 N
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Voltage -10...150V (multi-layer)
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A Case Study: HONDA CityA Case Study: HONDA City EngineEngine
Battery
Throttle Body
Master Cylinder
Engine (Transverse mounted)
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Air Filter
Alternator
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HONDA City Engine sensors
IAT Sensor
Manifold Air TemperatureManifold Air Temperature sensor
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measures the temperature ofincoming air.
Manifold Absolute PressureManifold Absolute Pressure
sensor measures the ve
pressure in the inlet manifold.
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Purge Control Valve
part of the
evaporative
emission control
Throttle BodyPurge Control Solenoid
HONDA City Engine sensors
system.
TPS- Throttle
Position Sensor
measures the throttle
valve opening.
ISC Solenoid
Idling speed control
TPS
Wiring Harness
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solenoid controls the
flow of air during
idling of engine tocontrol the speed of
engine within the
specified range.
ISC Solenoid
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MAP SensorHONDA City Engine sensors
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Fuel Injector
Starter Motor
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HONDA City Engine sensors
sensors mounted on
engine.
Senses the coolant
temperature
surroundin the en ine
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cylinder in the engine
block.
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Master CylinderHONDA City Engine sensors
Brake Fluid Level sensor
A/C system Pressure Sensor
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Completely assembled Porsche engine
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Cam shaft position sensor
CAM Shaft
Cam shaft sensor mounting
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The cam shaft sensor is mounted on the engine near the camshaft.
It is a Hall effect transducer which generates an electricalsignal that is proportional to the rotation of the cam shaft.
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Knock Sensor
Knock sensor mounting
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The knock sensor is mounted on the engine block.
It is essentially an accelerometeraccelerometer which generates anelectrical signal that is proportional to the vibration ofthe cylinder block.
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Crank shaft position / Speed sensor
Crankshaft
position/speed sensor
is mounted near the
Fly wheel
flywheel.
The flywheel will have
projections that
generate the pulses.
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handled by the ECU to
generate the necessary
information.
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Oxygen Sensors
The oxygen sensorsoxygen sensors are
also known as theLambda SensorsLambda Sensors.
ey are oca e n eexhaust gases leavingthe cylinder.
They measure theamount of oxygen
present in the exhaust
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gases.
This information is usedto control the emission
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Summary Various types of automotive sensors and
actuators have been discussed in terms of
wor ng pr nc p es, app ca ons n
automotive electronic systems.
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