Bosch Powertrain Sensors
Sensor Training 28.10.07
We Engineer Automotive Sensors
Gasoline Systems
MICO/GS-SI | 22/10/2007 | This is the exclusive property of Motor Industries Co Ltd. Without their consent, it may not be reproduced of given to third parties
Bosch Powertrain Sensors
Diesel System
Gasoline Systems
MICO/GS-SI | 22/10/2007 | This is the exclusive property of Motor Industries Co Ltd. Without their consent, it may not be reproduced of given to third parties
Bosch MAF Sensors
Agenda
Features & Benefits Technical Overview HFM5/6/7
Gasoline Systems
MICO/GS-SI | 22/10/2007 | This is the exclusive property of Motor Industries Co Ltd. Without their consent, it may not be reproduced of given to third parties
Bosch MAF Sensors
Hot-Film Mass Airflow Sensor
Features Digital/analog interface High level of tolerance/robustness Plug-in application without cylinder-housing possible Integrated temperature sensor (optional) Customer benefits Simplified application for gasoline and diesel engines by standardized characteristic curve and reduced packaging Low-emission engine management and reduced effort with exhaust-gas treatment
Gasoline Systems
MICO/GS-SI | 22/10/2007 | This is the exclusive property of Motor Industries Co Ltd. Without their consent, it may not be reproduced of given to third parties
Bosch MAF Sensors
HFM Measuring Principle
10
T
Frequency (kHz)
9 8 7 6 5 4 3
0
T2 T1
Heat ing zone Se Diap nsor hrag m
2 1
100 200 300 400 500 600
Mass Air Flow (kg/h)
Back flow Forward flow
Gasoline Systems
MICO/GS-SI | 22/10/2007 | This is the exclusive property of Motor Industries Co Ltd. Without their consent, it may not be reproduced of given to third parties
Bosch MAF Sensors
HFM6 Function - Frequency Ratiometric
Temperature Control Heater Control Unit ADC Ulf
Rh Rhf Rlf
Map T-Channel
Back end T
Freq Ubat
Evaluation Temperature Profile
RAB1 RAU2
Map m-Channel
GND
NTC + ADC Ubr Back end m MAF Signal [f]
RAU1
RAB2
Gasoline Systems
MICO/GS-SI | 22/10/2007 | This is the exclusive property of Motor Industries Co Ltd. Without their consent, it may not be reproduced of given to third parties
Bosch MAF Sensors
HFM7 Function - Frequency Absolute
Temperature Control Heater Control Unit ADC Ulf
Rh Rhf Rlf
HFM7 Electronics
Ubat GND NTC -
Evaluation Temperature Profile
RAB1 RAU2
Map m-Channel
NTC +
ADC Ubr
RAU1 RAB2
Back end m
MAF Signal [f]
Gasoline Systems
MICO/GS-SI | 22/10/2007 | This is the exclusive property of Motor Industries Co Ltd. Without their consent, it may not be reproduced of given to third parties
Bosch MAF Sensors
HFM7 Function - Analog
Temperature Control Heater Control Unit ADC Ulf
Rh Rhf Rlf
HFM7 Electronics
Ubat GND NTC +
Evaluation Temperature Profile
RAB1 RAU2
Map m-Channel
Uref
ADC Ubr
RAU1 RAB2
Back end m
+Ua MAF Signal [V]
Gasoline Systems
Bosch MAF Sensors
Implementation of improvements: housing plug-in
Optimization of Realization in cylinder housing Not applicable Pulsation performance CI Robustness Pressure drop, inflow sensitivity RP
2000
2005
plug-in
e.g. CL
ID
IP
199699
2003
2007
Gasoline Systems
MICO/GS-SI | 22/10/2007 | This is the exclusive property of Motor Industries Co Ltd. Without their consent, it may not be reproduced of given to third parties
Bosch MAF Sensors
Aerodynamic Design of HFM7 IP*
Cross-section based on wing geometry Turbulators define flow condition Vortex generators stabilize airflow Bypass outlet sideways and winglet reduce wall influence Benefits Lowest pressure drop of the HFM-series Improved signal noise Smaller than ID Plug-in sensor Lower flow disturbance sensitivity Improved pulsation behavior
*IP: Integrated deflection and reduced pressure
Gasoline Systems
10
MICO/GS-SI | 22/10/2007 | This is the exclusive property of Motor Industries Co Ltd. Without their consent, it may not be reproduced of given to third parties
Bosch MAF Sensors
Integrated Deflection Working Principle
Water and dust are flow through the main outlet due to their inertia Measured airstream is cleaned
Sensing Element Bypass Outlet Flow-splitting Edge
Only clean air in measuring duct
Air inlet
clean air air with dust
Mainflow Outlet
Gasoline Systems
air with water
11
MICO/GS-SI | 22/10/2007 | This is the exclusive property of Motor Industries Co Ltd. Without their consent, it may not be reproduced of given to third parties
Bosch Low Pressure Sensors
Agenda
Features & Benefits Design & Chip Overview
Gasoline Systems
12
MICO/GS-SI | 22/10/2007 | This is the exclusive property of Motor Industries Co Ltd. Without their consent, it may not be reproduced of given to third parties
Bosch Low Pressure Sensors
Low-Pressure Sensor
Features Silicon micromechanics, 1-chip-concept Standardized design for different applications Absolute, differential, relative pressure applications Customer benefits High accuracy Short response time Compact Diagnostics for short-circuit and wire breaks Customer specific modifications easy to realize Optionally integrated temperature sensor reduces wiring
Gasoline Systems
13
MICO/GS-SI | 22/10/2007 | This is the exclusive property of Motor Industries Co Ltd. Without their consent, it may not be reproduced of given to third parties
Bosch Low Pressure Sensors
BOSCH Low Pressure Sensor Generations
Pre-mold, 1-Chip
Improving
Ceramic Substrate, 1-Chip
packaging complexity reliability
TO-Cell, 1-Chip
DS-S3* DS-S2
DS-S
SOP <1995
Gasoline Systems
* Diesel SOP 2008
SOP 1998
SOP 2006
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MICO/GS-SI | 22/10/2007 | This is the exclusive property of Motor Industries Co Ltd. Without their consent, it may not be reproduced of given to third parties
Bosch Low Pressure Sensors
Functional Parameters
Transfer function and accuracy (e.g. 10 - 115 kPa)
UA= (c1pabs+c0)US
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
5 4,65
1.35 1,6
Toleranz in kPa
0 10 -1,6 35 95 115
-1.35
-4 Absolutdruck pabs in kPa
4 3,5 3 2,5 Faktor
0,4 0 0 10 Absolutdruck pabs in kPa 115
Ausgangsspanung UA in V
2 1,5 1 0,5 0 -50 -40
10 Temperatur t in C
85
130
150
Gasoline Systems
15
MICO/GS-SI | 22/10/2007 | This is the exclusive property of Motor Industries Co Ltd. Without their consent, it may not be reproduced of given to third parties
Bosch High Pressure Sensors
Agenda
Features & Benefits Design & Function
Gasoline Systems
16
MICO/GS-SI | 22/10/2007 | This is the exclusive property of Motor Industries Co Ltd. Without their consent, it may not be reproduced of given to third parties
Bosch High Pressure Sensors
High-Pressure Sensor for CRS Application
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 MPa
Customer benefits Very high sensor accuracy: higher metering accuracy Resistant to media, hermetic sealing of measured media Variation of plug connection and hydraulic connection possible 5V or 3.3V characteristic curve (optional) Easy assembly, vibration-resistant, high thermal stability Fault diagnostics using signal-range check
Gasoline Systems
17
MICO/GS-SI | 22/10/2007 | This is the exclusive property of Motor Industries Co Ltd. Without their consent, it may not be reproduced of given to third parties
Bosch High Pressure Sensors
Measuring Principle
V 4,8 4,5
Sensorelement
Output Voltage
0,5 0,2 0 Pressure 14 MPa
Gasoline Systems
18
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Bosch Crank Sensors
Agenda
Features & Benefits Functional principle
Gasoline Systems
19
MICO/GS-SI | 22/10/2007 | This is the exclusive property of Motor Industries Co Ltd. Without their consent, it may not be reproduced of given to third parties
Bosch Crank Sensors
Crankshaft Sensor DG-6P
Features 2-wire Variable Reluctance principle 100% compatible to predecessor DG6 Output Voltage > 1650 mV (@ 416 RPM) Wide temperature range
Customer benefits Increased robustness (improved Thermal Shock resistance) Reduced drift over lifetime Well-proven design and manufacturing concepts
Gasoline Systems
20
MICO/GS-SI | 22/10/2007 | This is the exclusive property of Motor Industries Co Ltd. Without their consent, it may not be reproduced of given to third parties
Bosch Crank Sensors
DG-6P Functional Principle
Function principle Signal generation
Output versus speed
Signal with a 60-2 target
Gasoline Systems
21
MICO/GS-SI | 22/10/2007 | This is the exclusive property of Motor Industries Co Ltd. Without their consent, it may not be reproduced of given to third parties
Bosch Crank Sensors
Comparison DG-6 versus DG-6P
DG-6 tightness; water resistance mounting tolerance resistance against external fields thermal shock life time > 160 Tkm
IPX4K
DG-6P
IPX6K / IPX9K
air gap 0,3 1,8 mm
air gap 0,3 1,8 mm
H= 500 kA/m
H= 2000 kA/m
300 cycles - 40 / +130C
600 cycles - 40 / +150C respectively 1800 cycles -30 / +120 C
Passenger car: 300,000 km Commercial vehicle: 1,000,000 km
Gasoline Systems
22
MICO/GS-SI | 22/10/2007 | This is the exclusive property of Motor Industries Co Ltd. Without their consent, it may not be reproduced of given to third parties
BOSCH CAM Position Sensors
Agenda
Features & Benefits Design & Function
Gasoline Systems
23
MICO/GS-SI | 22/10/2007 | This is the exclusive property of Motor Industries Co Ltd. Without their consent, it may not be reproduced of given to third parties
BOSCH CAM Position Sensors
Camshaft Sensor PG-3.9
Features Single Hall principle / single-track target wheel True-Power-On Twist insensitive mounting Wide temperature range Customer benefits Robust High accuracy Low mass Small packaging size and functional diameter (11 mm) Digital output logic reversible Low consumption current High EMC/ESD Robustness
Gasoline Systems
24
MICO/GS-SI | 22/10/2007 | This is the exclusive property of Motor Industries Co Ltd. Without their consent, it may not be reproduced of given to third parties
BOSCH CAM Position Sensors
Functional Principle
Variation of magnetic field (B) during one target wheel rotation
tooth switching threshold
electrical outputsignal Example Gasoline target wheel (20/70 quick-start)
Gasoline Systems
0
slot
45 90 135 180 225 270 315 360
target wheel angle []
25
MICO/GS-SI | 22/10/2007 | This is the exclusive property of Motor Industries Co Ltd. Without their consent, it may not be reproduced of given to third parties
BOSCH CAM Position Sensors
PG-3.9 Specification (with 20/70 target wheel)
1
Speed (Cam) Airgap Temperature range Supply voltage Supply current Output current Leakage current Falltime (high low) Risetime (low high) Accuracy (full operate range) Repeatability (3s)
0 ... 4500 rpm 0.1 ... 1.8 mm 1 (2,0 mm 1, 2) -40C ... +150C (100h@160 C) 4.5 V ... 16 V 10 mA 20 mA 10 A 1 s 20 s (with Rload = 3.3 k) 1 CAM 1, 3 0.26 CAM 1
depends on target wheel 2 with reduced accuracy but True-Power-On-functionality 3 with compensation of systematic errors
Gasoline Systems
26
MICO/GS-SI | 22/10/2007 | This is the exclusive property of Motor Industries Co Ltd. Without their consent, it may not be reproduced of given to third parties
BOSCH CAM Position Sensors
Optimum Design PG-3.9 Target Wheel
Optimum design of the target wheel
(bottom read, radial sensing) single track diameter 54 mm tooth height 5 mm (difference between Bmax and Bmin ) slot width 10 mm (back-bias-field reaches Bmin) (side-looking of sensor ) thickness 8 mm (lateral displacement of sensor )
Gasoline Systems
27
MICO/GS-SI | 22/10/2007 | This is the exclusive property of Motor Industries Co Ltd. Without their consent, it may not be reproduced of given to third parties
Bosch Temperature Sensors
Agenda
Features & Benefits Function
Gasoline Systems
28
MICO/GS-SI | 22/10/2007 | This is the exclusive property of Motor Industries Co Ltd. Without their consent, it may not be reproduced of given to third parties
Bosch Temperature Sensors
Water/Oil Temperature Sensor
Features temperature range: -40C +130C (+150C) supply voltage: 5V (only with series resistance) response time ((63): 20 80C): 10 15 sec vibration proof: max. a(sin) = 300 m/s isolation: 500V for 13 sec. durable against operating materials (fuel, oil, battery acid, ...) durable against water according DIN 40 050, IPX4K 9K Customer benefits engine coolant water / oil temperature can be mounted on engine block for air cooled engines modifications with small complexity: NTC (accuracy), screw thread (M12x1,5 or M14x1,5), length of shaft, connector (compact or Jetronic), flat connector (tin or gold), captive sealing-ring cooper or aluminum)
Gasoline Systems
29
MICO/GS-SI | 22/10/2007 | This is the exclusive property of Motor Industries Co Ltd. Without their consent, it may not be reproduced of given to third parties
Bosch Temperature Sensors
Function
Characteristic R=f(T)
100000
Nominal resistance 20C 2.5 k 6% 100C 0.186 k 2%
Resistance R in Ohm
10000
Nominal voltage 5 0.15 V Operation only permitted with Electronic Control Unit (ECU) Temperature time constant checked in water/oil 63 15s
1000
100
10 -40 -20 0 20 40 60 80 100 120 140
Temperature t in C
Gasoline Systems
30
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Bosch Accelerator Pedal Sensors
Agenda
Features & Benefits APM output data Electrical characteristics
Gasoline Systems
31
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Bosch Accelerator Pedal Module
Accelerator Pedal Module
Features Separate (FPM1) or integrated potentiometers (FPM1.2) with two potentiometers for redundancy Integrated hall sensor with 2 output signals (FPM 2.2) Integrated hall sensor with digital output (FPM2.3) Customer benefits Innovative and robust engineering technology Vehicle specific application Proven design with twin-potentiometer for diesel applications Used in passenger and light duty applications
Gasoline Systems
32
MICO/GS-SI | 22/10/2007 | This is the exclusive property of Motor Industries Co Ltd. Without their consent, it may not be reproduced of given to third parties
Bosch Accelerator Pedal Module
APM- Output Data
Sensor Data : Electrical Characteristic
F Force s Pedalway Low Idle Position
Gasoline Systems
Mechanical Data : Force-Way Characteristic
Full Load Position
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Bosch Accelerator Pedal Module Electrical Characteristics - Function Voltage/Pedalway
Legend :
u/U Signal 1 P 1 u1/U1 MS
U : Voltage ref. U = 5 0,3 V P1: Low Idle : 0,150,02 u/U (over lifetime) Mechanical backstop : 0,820,04 u/U (over lifetime). P2: P2 = P1/2 0.014 (u/U)
u1x/U1
Lx
u2/U2 MS Signal2 P 2
Linearity P1 Lx = 0,02 (u/U) Synchronity P1 = 2*P2
u2x/U2 u1/U1 LL u2/U2 LL Mechanical backstop (low-idle) sX
Mechanical backstop
s[mm]
Gasoline Systems
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MICO/GS-SI | 22/10/2007 | This is the exclusive property of Motor Industries Co Ltd. Without their consent, it may not be reproduced of given to third parties
Bosch Powertrain Sensors
THANK YOU
In case of questions you can contact by e-mail: [email protected] [email protected]
Gasoline Systems
35
MICO/GS-SI | 22/10/2007 | This is the exclusive property of Motor Industries Co Ltd. Without their consent, it may not be reproduced of given to third parties
