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Glow Plug Integrated Piezo-Ceramic Combustion Sensor for Diesel Engines
Gérard TROY, Siemens VDOAlain RAMOND, Siemens VDOSandro GORETTI, Federal Mogul
Combustion sensingNOx (g/km)0.0 0.1 0.2 0.3
PM (g
/km
)
0.00
0.02
0.04
0.06
Japan 2005Japan 2005
LEV (CARB LEV I)
EURO IV
Tier 2, Bin 5Tier 2, Bin 5Euro VEuro V
New emission legislations for Diesel engines
HCCI with CLCCNeed of a pressure sensor
Page 3
Pressure sensor portfolio
GPCSGlow Plug Combustion sensor
GPPSGlow Plug Pressure sensor
NICSNon intrusive Combustion sensor
Sensing principle :
Measurement of the deformation of the probeAdvantages :
- Direct pressure sensor ( Can be calibrated )- Robustness
Sensing principle :
Measurement of the deformation of the cylinder headAdvantages :- Low cost- RobustnessDrawbacks :- Need a calibration on engine
SAPS Stand alone Pressure sensor
Sensing principle :
Same configuration than GPPS but without the probe
Combustion sensing family( Cylinder head deflection measurement )
Pressure sensing family( Direct pressure measurement )
Sensing principle :
Same as GPCS
Advantages / Drawbacks:
- Do not require a hole in the cylinder
Page 4
Combustion sensor : Measurement of cylinder head deflection versus direct measurement
GPCS: sensitive to
cylinder head deflection
GPPS: sensitive to glow plug
deflection only
Page 5
Pressure sensor portfolio
GPCSGlow Plug Combustion sensor
Passive
GPPSGlow Plug Pressure sensor
Active
Calibration error
Ageing
sensitivity variations
hysteresis
error ( HF noise )
300%
0%1%2%3%4%5%6%7%8% P
rice
Acc
urac
y ( +
/-)
100%
200%
GPCS GPPS
Page 6
Combustion sensing family
GPCSGlow Plug Combustion sensor
NICSNon intrusive Combustion sensor
Sensing principle :
Measurement of the deformation of the cylinder headAdvantages :- Low cost- RobustnessDrawbacks :- Need a calibration on engine
Sensing principle :
Same as GPCS
Advantages / Drawbacks:
- Do not require a hole in the cylinder
ShellElectrode Interface“Spring Zone”
Ceramic TubeSensor Electrodes
Piezo
Passive sensor:• signal conditioning in ECU
Page 7
GPCS : Sensing principle
Piezo ceramic based product
Manufacturing process similar to knock sensor processRobust and environmentally sealedVery long time stability, (very low ageing rate of the piezo ceramic)High signal to noise ratio : Low sensitivity of the sensor to engine vibrations
Page 8
GPCS : Accuracy
Signal to noise ratio
SNR always below +/- 1 bar
Hysteresis
050
100150200250300350400
0 0.5 1Pressure on piezo (MPa)
Ele
ctric
al c
harg
e (p
C)
2% hysteresis, repeatable, can be compensated in ECU
Page 9
GPCS : Sensitivity change
94%
95%
96%
97%
98%
99%
100%
101%
0 20 40 60 80 100 120 140 160Load (Nm)
Rel
ativ
e se
nsiti
vity
RPM 2000
RPM 3000
RPM 4000
Change of sensitivity over temperature: 5%
- Very repeatable
- Easily compensable in open loop
Change of sensitivity over Engine conditions
(Load / rpm): < +/- 2%
-1%
0%
1%
2%
3%
4%
5%
40 50 60 70 80 90 100
Water coolant temperature (°C)
Sens
itivi
ty c
hang
e
Page 10
GPCS Sensor Error summary
0123456789
10
0 50 100 150 200Pressure (bar )
erro
r (ba
r) HF noiseHysteresisSensitivity
variationsAgeing
+/- 4 % accuracy
GPCS accuracy is 4% without calibrationGPCS robustness demonstrated on engine testsGPCS SNR evaluated successfully for accurate measurement
of MFB ( location of the 50% of the heat release curve ), thus enabling HCCI control
Page 11
GPCS as used for HCCI control:Sensor signal is used to compute MFB_50% angleECU is handling following operation:
charge to voltage conversionconstant amplification (no open loop compensation)low pass 5Khz filteringsignal pegging (offset compensation) @ constant crank angle
2 different engines have been used for tests:
GPCS within engine control strategy
Ref sensor
Raw GPCS signal
Filtered GPCS signal
MFB_50% computation
cte offset
Page 12
Pressure sensing family
GPPSGlow Plug Pressure sensor
Sensing principle :
Measurement of the deformation of the probeAdvantages :
- Direct pressure sensor ( Can be calibrated )- Robustness
SAPS Stand alone Pressure sensor
Sensing principle :
Same configuration than GPPS but without the probe
Probe stress measurement
Active sensor calibrated
Conditioning in the sensor
Standard analog output
Page 13
GPPS : Sensing principle
Use of piezo-electric elementMiniaturization of the sensor in the bottom
of the Glow Plug shell ( M8 )Use of a ceramic heating probeAssembly of the ceramic probe on a "Thick
membrane "Solution fully sealed, not sensitive to dust
contaminationElectronic integrated into the Glow Plug shellCompact integrated connector within automotive
standards
Page 14
GPPS : The piezo electric element
-10
-50
5
10
1520
25
30
-1.5 -1 -0.5 0 0.5
applied stress (MPa)
Cha
rge
Den
sity
(pC
/mm
2)
0
5
10
15
20
25
0 200 400 600 800 1000 1200Preload on the piezo ( N )
Piez
o se
nsiti
vity
( pC
/N )
Highly stable poly crystalline piezo electric element
Lead free compositionHigh Curie temperature : 650°CNo hysteresis ( < 0.1 % )Low sensitivityTime stability demonstrated in other product
application with 500 °C operating temperatureNo change of sensitivity versus preload and
temperature ( < 1% )
Page 15
GPPS : The ceramic probe technology
Ceramic Technology for the "Glowing Part" has been developed byFederal Mogul in order to fulfil new Customer's requirements.
The Federal-Mogul Ceramic Glow Plug Technology is a multi-layer structure made of a silicon nitride substrate with different percentage of Molybdenum Di-Silicide to create conductive paths
The heating part is the tip of the ceramic probe, where the major amount of electrical resistance is concentrated
The technology is fully protected by several worldwide patents
Ceramic heating element are proposed by Federal Mogul for standard plugs, and for GPCS, though GPPS will be available withCeramic probe only
Page 16
1.08 1.09 1.1 1.11 1.12 1.13-10
0
10
20
30
40
50
60
70
80
time (s)
bar
3000 RPM / 80 Nm
GPPS : Example of engine test results
Page 17
1.15 1.155 1.16 1.165 1.17 1.175 1.18 1.185 1.19 1.195 1.2
0
20
40
60
80
100
120
time (s)
bar
GPPS : Example of engine test results
3000 RPM / 120 Nm
Page 18
GPPS : Example of engine test results
1.02 1.03 1.04 1.05
0
20
40
60
80
100
time (s)
bar
1.03 1.04 1.05
-5
0
5
time (s)
erro
r (b
ar)
GPPS High frequency noise below +/- 0.5 % of FSO
Page 19
-50 0 50 100 150-50
0
50
100
150
reference sensor (bar)
GP
PS
(ba
r)
GPPS Hysteresis below 0.5 %
GPPS : Hysteresis
Page 20
-5-4-3-2-1012345
Idle
2000
rpm / 2
0 Nm
2000
rpm / 8
0 Nm
2000
rpm / 1
20 N
m30
00 rp
m / 20 N
m30
00 rp
m / 80 N
m
3000
rpm / 1
20 N
m40
00 rp
m / 20 N
m40
00 rp
m / 80 N
m
Sens
itivi
ty v
aria
tion
( %
Sensitivity variations always below 1%
GPPS : Sensitivity changes versus engine conditions
Page 21
GPPS : Sensor Error summary
Target of GPPS : 3.5 % Accuracy over lifetimeIncluding calibrationSensor time stability will be soon demonstrated by engine endurance tests
0123456789
10
0 50 100 150 200Pressure (bar )
erro
r (ba
r)
HF noiseHysteresis / Thermal choc errorSensitivity variations
Ageing
+/- 3.5 % accuracy
Calibration error
Page 22
GPPS : Heat release monitoring
Page 23
Page 24
Thank you for your attention !