Supplier Spotlight

Show Reviews

Automotive Testing Expo Europe 2017 Show Review

Click here to read

 

Automotive Testing Expo Europe 2016 Show Review

Click here to read

 

Automotive Testing Expo Europe 2015 Show Review

Click here to read

 

Automotive Testing Expo North America 2014 Show Review

Click here to read

 

Automotive Testing Expo India 2014 Show Review

Click here to read

 

Latest Video


JLR heads to LA with I-Pace

LV

Engineer Simon Patel takes potential I-Pace customer Ann Voyer on a long-distance real world road trip from Sunset Boulevard, Los Angeles to Morro Bay, San Luis Obispo to test the vehicle's range and durability

Click here to watch the video


Waymo unveils self-driving cars

LV

Waymo, which started as the Google self-driving car project in 2009, is ready for the next phase. Fully self-driving vehicles are currently being tested on public roads, without anyone in the driver’s seat.

Click here to watch the video


As vehicle developers and suppliers continue to advance their software programs, ATTI wants to know, has simulation software established itself as the single most vital piece of equipment during a development program?

Articles

« back to listing

Measuring pressure in tough conditions

FPT Motorenforschung, a Swiss manufacturer of engines for commercial vehicles, construction equipment and agricultural machinery, uses Keller’s M5 pressure transmitters in its test benches to achieve reliable, precise measurement results

 

“The engines that we develop and test in our facility need to meet the most stringent quality requirements in terms of materials, emissions and efficiency,” noted Rainer Linsenmeyer, head of test engineering and electronic measurement at FPT Motorenforschung.

“This means that when we examine the engines on our test benches, we have to consider all the variables that influence how well they work, so we need precise measuring equipment that delivers reliable readings even in the conditions of an engine, which can sometimes vary considerably and be extremely tough.”

Keller developed its sensors to meet the company’s requirements in engine development. This work focuses primarily on reducing exhaust emissions and achieving a high power density, low fuel consumption, a long service life and maximum reliability. An engine’s efficiency depends largely on the extent to which the flow of air into the combustion chamber and that of the exhaust gases back out again are unimpeded. The pressure here will be under 10 bar. Extremely accurate and highly dynamic measurement is essential.

Several of Keller’s M5 devices are used at various places on the engine during tests. To obtain a reliable analysis of pressure conditions and losses, it is important to take measurements as close as possible to the individual cylinders on the inlet side. The varying geometry of the intake manifold poses an additional challenge as it means that each cylinder is supplied with a different amount of air, which should be avoided as much as possible. On the outlet side, too, the combustion gases in the individual cylinders can cause unwanted interactions between pressure surges or pulses. The pressure sensors measure these processes on the inlet and outlet sides locally and with a high level of phase fidelity.

The sensors must not be sensitive to structure-borne noise. The measuring slot should be sealable with a plug once measurements have been taken and should be as resistant as possible to air flows. This application can also lead to compensating currents of up to 40A being generated by the engine battery – these must not influence the sensor.

Keller’s sensors do not require bonding wires in the vicinity of the medium and there are no connectors between the sensor and the electronic system. This removes any additional contact resistances and sources of faults. The cable gland is hermetically sealed (IP67) to minimize external influences on the cable. Most of the electronic system is fitted externally, enabling it to be positioned in a noise-free area.

Potential uses

FPT Motorenforschung uses M5 sensors with electronic systems on all of its 30 engine test benches. The company takes measurements inside components such as oil, fuel and water pumps, injector lines, intercoolers, heat exchangers, and intake and exhaust ducts. Logging the pressure conditions enables any fluctuations, peaks or other generally unusual pressure phenomena to be detected.

The data obtained makes it easier to extrapolate the dynamic conditions inside the engines. For instance, a pressure loss of 1Pa at a volume flow of 1m³/s – typical values for the intake air volumes of large HGV engines – translates into 1W of lost performance. In practice, this means that a 50mbar fall in pressure results in a flow loss of as much as 5kW. Consequently, this value must be kept as low as possible to make the engine more efficient.

M5 sensors can also be used in the return pipes in injectors. Because of how they are designed, injectors generate a return flow through leaking and cooling. The pressure conditions in these pipes are also measured and optimized, with a pressure range from 1 to 5 bar. Oil pressure is a further critical factor in engine efficiency.

“When measuring oil pressure it is particularly important to find a sensor that is small enough. This is because smaller sensors have less of an impact on the actual flow conditions. Also, there is often very little space to install them with this kind of application, so a standard sensor was never an option. The M5 sensor ticks all the boxes,” said Linsenmeyer.

“One particular benefit is the fact that, after testing is complete, the openings for the sensors can be sealed using a simple M5 plug almost as if nothing had changed. This means that any modifications to the system won’t distort the results of other tests. We’re delighted that, in the M5 sensor, we’ve found a reliable measuring instrument that can be put to a wide range of uses on our test benches.”

The M5 series
Pressure sensors in the M5 HB series are designed to deliver extremely fast and precise measurements to an accuracy of 0.1% FS up to 180°C. The pressure connection to the M5 fine thread is designed for both static and dynamic measurements such as pressure pulses. Thanks to their miniature size, these sensors are ideal for local measurements.

The M5 sensor also has a low dead volume and good venting capability. It uses a rear-side technology without a transfer medium that also helps to minimize the attenuation of the measurement signal. No sealants, adhesives or capillaries are required.

To prevent any unnecessary impact on flow conditions, the process connection should be as short as possible and, in terms of handling, be able to be installed easily even in narrow tubes. The sensor is thus also very lightweight and able to withstand rapid acceleration.

The M5 series is available with or without an electronic system and offers signal fidelity up to the limit frequency of 50kHz. The M5 HB pressure transmitters (i.e. with an electronic system) were optimized in line with FPT Motorenforschung’s technical specifications and have been in use for over two years.

February 6, 2017

 

Read Latest Issue
Read Latest Issue
RECEIVE THE
LATEST NEWS


Your email address:



Web Exclusives

Safer analysis of onboard chargers

How Keysight's compact, two-quadrant, regenerative power converter test solution with integrated safety features accelerates test time, and protects both users and devices under test
Click here to read more



SEAT uses HBM autonomous DAQ system

SEAT and Polytechnic University of Catalonia (BarcelonaTech) have jointly developed a unique data acquisition enabling more precise control over instrumented parts and the entire data acquisition process  
Click here to read more



Modern calculation management

The engineering department at Hitachi Construction Truck Manufacturing is taking steps to improve its rigid-frame hauling truck design through improving its analysis tools
Click here to read more



Traveling in a Volkswagen that is still to be developed

Volkswagen Group’s IT Virtual Engineering Lab has developed a virtual concept car using digital future technology
Click here to read more



The importance of software engineering

Tier 1 supplier GKN’s software and electronics manager, Michael Schomisch, discusses how software development is becoming increasingly important in vehicle testing
Click here to read more




Supplier Spotlight

Supplier SpotlightClick here for listings and information on leading suppliers covering all aspects of the automotive testing industry. Want to see your company included? Contact jason.sullivan@ukimediaevents.com for more details.

Submit your industry opinion

Industry BlogDo you have an opinion you'd like to share with the automotive testing community? Good or bad, we'd like to hear your views and opinions on the leading issues shaping the industry. Share your comments by sending up to 500 words to john.thornton@ukimediaevents.com

Advertising

Recruitment AdTo receive information on booking an advertising banner please email jason.sullivan@ukimediaevents.com