Arvind PDF

Bosch Power-train /
Exhaust Sensors
Overview
Aravind K
Powertrain & Exhaust Sensor Division
Bosch Sensors Overview/Training:
Definition of Sensor
A sensor is a device which
measures a physical variable and
converts it into a electrical variable
which can be read by an
observer/control unit
E.g.:
a mercury thermometer converts
the measured temperature into
expansion and contraction of a
liquid which can be read on a
calibrated glass tube.
a thermocouple converts
temperature to an output voltage
which can be read by a voltmeter
2 Internal | DGS-ES/ENG-IN_Ak | 31/08/2016

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Bosch Limited 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Diesel Engine Layout | CV

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Mounting Location (spark ignited engine - PC)
Canister Non High Turbo- Solenoid

Carbon canister return pressure vacuum Camshaft valve
purge valve
valves pump reservoir phaser*
Air mass meter
Dump
valve
Injector Ignition coil/

spark plug Phase Waste
Intercooler sensor Gate actuator
Boost pressure Solenoid
temp. sensor valve
Fuel rail
Ambient Turbo
pressure charger
sensor Pressure
Throttle SCV1 Exhaust
sensor
Electronic device Temp. temp. Waste
control unit (ETC) Knock Gate
sensor sensor*
sensor
Oxygen
sensor
Speed
Accelerator sensor
pedal modul Oxygen
CAN sensor
Fuel Pre catalyst
Diagnosis pump
lamp module
Diagnosis
interface ETC = Electronic Throttle Control * option Main catalyst
Bosch components
Immobilizer Camshaft phaser: specifically for DI
intake and/or exhaust phasing 1 swirl control valve (on/off or continious)

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Bosch exhaust and powertrain sensor portfolio
Sensor portfolio overview
Exhaust & powertrain sensors
Mass Air Flow Sensor High Pressure Sensors
(HFM) (RPS, HPS)
Pressure Based Air

Flow Meter Throttle Position
(PFM) Sensor
NOx Sensor (TPS)
(EGS-NX)
Low Pressure Sensors

Oxygen Sensor (LPS)
(LS)
Speed Sensor Turbo Charger

Exh Temp Sensor (RS-T1)
(EGS-T)
Knock Sensor
(KS) Camshaft Position Sensor
(CPS, PG)
Particulate Matter
Sensor Temperature Sensor
(EGS-PM) (TS) Rotational Speed Sensor Crank
(RSC, DG)

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Speed &
Pressure Air mass position Knock Temperature
sensors sensors sensors sensors sensors
(xPS) (xFM) (RSx, CPS, (KS) (TS)
TPS)
Powertrain sensor portfolio DGS-ES

Product Area | Powertrain Sensors

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Low Pressure Sensor - LPS
Features
Silicon micromechanics, 1-chip-concept

Standardized design for different applications
DSS3
Absolute, differential, relative pressure applications
Pressure range 0 400 kPa Max-absolute
Operating temperature range -40 . 130C(optional 150C)
Working Principle : Wheatstone Bridge(Pressure transducers)
Application
DSS3-TF
Measures Intake Manifold Air Pressure & Temperature
Measures Boost pressure.
Facts and Figures

Mounting Location
SOP : 2006
SOP(India) : 2010 Intake manifold
After turbo-charger

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Functional Principle 5
4,65
Ausgangsspanung UA in V
0,4
0
0 10 115
Absolutdruck pabs in kPa
Transfer function and accuracy 4
(e.g. 10 - 115 kPa) 3,5
UA= (c1pabs+c0)US 2,5
Faktor
2
UA = output voltage in V
1,5
US = supply voltage in V
1
pabs = absolute pressure in kPa
0,5
c0 = -0,1/105
c1 = 0,85/105 kPa-1 0
-50 -40 10 85 130 150
Temperatur t in C
Use : To measure Intake mainfold pressure & Temp.

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Differential Pressure Sensor DS-D2
Features
Pressure ranges from 0 to 125 kPa
Silicon MEMS Sensor chip (pressure transducer with integrated
electronic circuit) on hybrid ceramic
1-Chip concept with mechanical differential pressure measurement
Sensing element protected by media resistant gel
Media robust design for DPF application
Operating temperature range -40 . 130C(optional 150C)
Application
Measures pressure & temperature across EGR unit & DPF.
Facts and Figures
SOP : 2006
Mounting Location
Across DPF EGR Exhaust Gas Re-circulation

After EGR DPF Diesel Particulate Filter

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High Pressure Sensor
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, 240, 270 Mpa
Temperature range -40C/+130C(optional 150C)
Application
Measures the pressure of fuel in the rail Diesel Application.

Measures the pressure of fuel in GDI application.
Facts and Figures
SOP : 2001 Mounting Location
On the fuel rail

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Functional Principle
V
4,8
4,5
Output Voltage
Sensorelement
0,5
0,2
0 14 MPa
Pressure

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Hot Film Air Mass sensor (HFM8)
Features
Reduced air mass tolerances and improved pulsation behavior
New part tolerance: 1.5%*
Lifetime tolerance: 3.5%*
Pulsation error : 6%*
Flexible modular system:
Optional integration of additional pressure-, temperature- and humidity-
sensor / SENT or FAS interface / 5V or 12V supply voltage / Optional
applicable digital signal filters, Optional Chipheating function
9 Reduced power consumption < 20mA (for standard sensor)

Working Principle : Wheatstone Bridge(Thermistors)
65
Measures in mm Application
34
Measures the mass(kg/hr) & temperature of Intake air.
Humidity & pressure measurement options available.
Facts and Figures

AIS Air Intake System
After Air Filter in the AIS
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Output signal as a function of
Airmass
10
T 9
Frequency (kHz)
7
0 6
T2 5
T1
4
3
100 200 300 400 500 600

Mass Air Flow (kg/h)
Back Forward
flow flow

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Pressure Based Air Flow Meter - PFM
Features
Air flow measurement using dynamic pressure
Engine near, compact mounting position after charge air cooler
Measurement of dynamic pressure (Pd), reference pressure (PS)
and temperature (T)
Calculation of the air mass on basis of Bernoulli-equation
Suitable for off-highway application
Working Principle : Bernoulli equation + Ideal Gas equation +
Conservation of mass
Application
Measures the mass(kg/hr) & temperature of Intake air.

Preliminary Design Functional
Sample (PFM)
Facts and Figures Mounting Location
SOP(pilot): 12/2017 After Air Filter in the AIS

AIS Air Intake System

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Functional principle
Measurement of dynamic- (Pd) and reference pressure (Ps) by two pressure sensors
(p and Ps); measurement of temperature (T)
Air mass calculation:
Ps
Air
(Ps)
T
Temperature
(T)
Ptot
Integrated Sensors :
Fig. acc. To Prandtl tube principle
Robust measurement of air mass flow

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Knock Sensor KS-4
Features
Broadband type, 5 to 22 kHz
Linear characteristics over large frequency range
30mV/g at 5 kHz, active output
KS-4S
Standard version: -40 ... 130C
Extended heat version: -40 ... 150C
Technology: piezo-ceramic ring
Engine protection from uncontrolled combustion
Working Principle : Piezo-electric.
KS-4K
Application
Senses the engine-knocking/vibrations
Facts and Figures
On Engine block near cylinders

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piezo effect Characteristic curve U = f ( f )

mV/g
50
40
30
20
10
a Q/C = U excitation by acceleration 0 5 10 15 20 kHz

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Water/Oil Temperature Sensor
Features
Temperature range: -40C +130C (optional 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 1 3sec.
Durable against operating materials (fuel, oil, battery acid, ...)
Durable against water according DIN 40 050, IPX4K 9K
Working Principle : NTC Negative temperature coefficient
Application
Measures Engine coolant water / oil temperature
Facts and Figures
SOP(India): 2011 Mounting Location
On Engine block for air cooled engines

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Characteristic R=f(T)
principle circuit diagram 100000
5V
10000
additional
Resistance R in Ohm
resistor
e.g. 1 k
1000
100
NTC
10
-40 -20 0 20 40 60 80 100 120 140
Te mpe rature t in C
- Electrical resistance changes with temperature (thermistor)

- Resistance decreases when warming up

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Crankshaft Sensor DG-6
Features
2-wire Variable Reluctance principle

Speed range from 20 7000 rpm
Wide temperature range -40 ... 130C(optional 150C)
Working air gap range 0.3 to 1.8 mm
Available as plug-in or cable type.
Typical application: Crankshaft sensor with 60-2 teeth target
Working Principle : Faradays law of electro-magnetic induction
Application
Measures speed of the crank wheel/engine.
Facts and Figures

SOP(India): 2010 On Crank Wheel/fly wheel
Crank pulley

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Function principle Signal generation
Output versus speed Signal with a 60-2 target

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Crankshaft Sensor DG-23/DG-23i
Features
Direction rotation detection
Multi-Hall principle / single-track target wheel
High repeatability( 0.04 CRANK 1,3)
Wide speed range from 0 10000 rpm
Reverse speed range upto . 5000 rpm
Working Principle : Hall Effect
Application
Measures speed of the crank wheel/engine.
Facts and Figures
On Crank Wheel/fly wheel

Crank pulley

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Speed Sensor for Turbo Charger - RS-T1
Features
Detection of each compressor blade up to 400 000 rpm T/C speed
Integrated high temperature electronics for best EMC behavior
Temperature range up to 200 C (sensor head)
Frequency signal comparable to a speed sensor
No additional ASIC in ECU required
Working Principle : Faradays law of electro-magnetic induction
Application
Measures the speed of the turbo-charger
Facts and Figures

SOP : 01/2016 Mounting Location
On the turbo-charger

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Functional Principle Magnet
Sensing coil
Target wheel profile
Air gap range up to 2 mm (blind hole)

at the sensor tip:
Ambient temperature -40 C ... +180 C
(short term +200 C)
Magnet Rotation speed ca. 10 400103 rpm
Coil / Signal band width / 2 kHz ... 70 kHz
Measurement principle Inductive passive

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Cam Position sensor PG-3.8 /-3.9 / CPS4
Features
Single Hall principle / single-track target wheel
PG3.9 True-Power-On
Twist insensitive mounting
Small sensor diameter 11.3 mm (PG-3.9)
Working Principle : Hall effect
Application
PG3.8
Determines the position of the camshaft
CPS4
Mounting Location
Facts and Figures Rear-end of the cam shaft
SOP : 2003

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Functional principle
Basics of Application. Magnetic induction B depending on wheel angle
B tooth
switching
threshold
electrical
output- slot
signal
0 45 90 135 180 225 270 315 360
angle of target wheel

target wheel

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Throttle Position Sensor
Features
Angle sensor with linear functional characteristic (Potentiometer)
Throttle valve angle 0..86
Minimum flange bore-to-bore distance 40 mm
Throttle shaft interface 8 mm with D-shaped cross-section
Supply voltage 5V
Temperature range -40..+130C
Working Principle : Potentiometer
Application
Determines the position of the throttle valve
Facts and Figures
Mounting Location
SOP(India) : 2016
On the throttle body

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Measure position of the throttle valve
TPS provides engine management system
with information regarding position of
throttle and therefore engine load - vital for
fuelling and ignition mapping for optimum
performance and efficiency

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Oxygen Nitrogen Oxide Particulate Matter Temperature
Sensors Sensors Sensors Sensors
(LS) (EGS-NX) (EGS-PM) (EGS-T)
Exhaust sensor portfolio DGS-ES

Product Area | Exhaust Sensors

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Planar Switching Type Lambda Sensor - LSF Xfour TSP
Features
Planar sensor element with thermo shock protection (TSP)
Fast light-off-time (< 12 s at 10,5 V)
Sensor readiness before due point end possible
Xfour typical advantages:
Compact design, pumped reference leads to improved resistance against
contamination, high peak-temperature robustness up to 1030C (300h)
and permanent operating temperature 980C
With Low temperature control (LTC):
Early signal availability at low sensor element temperature
Fast sensor readiness 10s after engine start
Working Principle : Nernst Principle + Ionization
Application
Measures the content of O2 in exhaust gas
Facts and Figures
Mounting Location
SOP : 2012
On the exhaust tail pipe
Pre/Post catalyst

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Exhaust gas Sensing cell

PO2
PO2 RT
US = In
4F PO2
Sensor Characteristic Curve

V
Reference Heater
Sensor voltage
air PO2 0.9
ZrO2-Ceramic 0.6
Ureg
Electrodes
Porous protective layer 0.3
Insulation
0
0 0.98 1.0 1.02
Normalized A/F ratio
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Planar Wideband Lambda Sensor LSU 4.9
Features
Fast sensor readiness after engine start due to Thermo-shock protection
(TSP) & Fast light-off (FLO 12s)
Lambda control for gasoline engines
Continuous signal & wide measurement range (0,70 air)
Planar sensor element with integrated, central heater
Robust sensor element design through pumped reference
High peak-temperature robustness up to 1030C (250h);
permanent operating temperature 930C
Trim resistor in connector housing
Application
Facts and Figures

Mounting Location
SOP : 2003 On the exhaust tail pipe
Pre/Post catalyst

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Lambdasensor-Diesel (LSU 5.1)
Features
New sensor design (sensor element and protection tube) optimized for
Diesel applications
Compact 4 wire sensor concept
Temperature requirements designed to suit diesel application
Enhanced soot robustness
LSU4.9 LS-Diesel
Thermal shock protection (TSP)
Application
LS-Diesel (LSU5.1)
Mounting Location
Facts and Figures On the exhaust tail pipe

Pre/Post catalyst
SOP : 2013

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IP ~ p O2
Exhaust: Outer pump
O2, CO, electrode
H2, HC
O2
Apply Voltage IP-Measure 12 e-
08
04
O2- Zircondioxide
measure chamber
state: target 450 mV
Inner Heater
Diffusion- pump- Reference air electrode
barrier electrode
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EGS-NX 2nd Gen (Nitrogen Oxides)
Features
SCU Digital output, CAN bus capable, enables for ...
Standardized protocol (e.g. SAE J1939) or customer-specific CAN
NOx and O2 signal
NH3 as an additional contribution to the NOx signal
125C environmental temperature SCU, engine mounting of SCU

possible
Specified for 6.000* h / 186.500 miles (300.000 km)
Additional pin for position detection / Sensor classified in QM system(ASIL)
Application
Measures the content of NOx & O2 in exhaust gas
Facts and Figures

SOP(PC) : 02/2015 Mounting Location
SOP(CV) : [12 V] 07/2016
[24 V] 01/2017 On the exhaust tail pipe
Post catalyst

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EGS-PM sensor
Features
OBD: DPF monitoring for US MY2013 and EU6 by direct measurement of
particulate matter downstream DPF.
Sensor equipped with active electronics in separate SCU
Sensing principle: resistivity measurement of deposited soot;
sensor regeneration by periodic heating.
Ceramic sensing element with integrated heater, temperature
sensing element and inter-digital electrodes.
Communication with ECU: sensor with CAN interface.
Electrical interface: 12V supply(PC), 24V(CV).
Working Principle : Resistance measurement
Application
Measures the amount of particulate matter from the exhaust
Facts and Figures

Mounting Location
SOP : 2014
Post catalyst

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(1) positioning of (2) protection tube bleeds off partial (3) protection tube guides partial gas
sensor in exhaust gas stream from main stream in pipe stream over interdigital electrodes
pipe (IDE)
electrode
electrode
exhaust gas
Sensorsubstrat
(4) soot accumulation on and (5) Growth of conductive soot paths

between interdigital electrodes (IDE) through continuous accumulation
Resistance between interdigital electrodes depends on soot adsorption

Periodic heating regenerates sensor surface by burning soot layer off

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EGS-T | Exhaust Gas Temperature Sensor
M12,
M14 Features
Pt200 sensor element
Intrusion depth 3 base variants for all automotive applications
25 80 mm Value: -40 C up to 800C
Performance: -40 C up to 950C
High-End: -40 C up to 1150C
Closed sensor housing
Wire harness length & connector Flexible design
according customer specification (wire Very fast response time & high accuracy over lifetime
harness length 200 mm 1500 mm) Very high thermal shock & thermal cycle robustness
Working Principle : PTC Positive temperature coefficient
Customer specific wire harness fixation
Application
Measures the temperature of the exhaust
Facts and Figures

Mounting Location
SOP : end 2018
Inlet/Outlet of EGR EGR Exhaust Gas Re-circulation
Before/after DPF DPF Diesel Particulate Filter
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Thank you for your attention
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Bosch Power-train /

2 Internal | DGS-ES/ENG-IN_Ak | 31/08/2016

3 Internal | DGS-ES/ENG-IN_Ak | 31/08/2016

Canister Non High Turbo- Solenoid

Injector Ignition coil/

4 Internal | DGS-ES/ENG-IN_Ak | 31/08/2016

Pressure Based Air

Low Pressure Sensors

Speed Sensor Turbo Charger

5 Internal | DGS-ES/ENG-IN_Ak | 31/08/2016

Powertrain sensor portfolio DGS-ES

6 Internal | DGS-ES/ENG-IN_Ak | 31/08/2016

Silicon micromechanics, 1-chip-concept

Facts and Figures

7 Internal | DGS-ES/ENG-IN_Ak | 31/08/2016

Transfer function and accuracy 4

(e.g. 10 - 115 kPa) 3,5

UA= (c1pabs+c0)US 2,5

Use : To measure Intake mainfold pressure & Temp.

Across DPF EGR Exhaust Gas Re-circulation

9 Internal | DGS-ES/ENG-IN_Ak | 31/08/2016

Measures the pressure of fuel in the rail Diesel Application.

SOP : 2001 Mounting Location

On the fuel rail

10 Internal | DGS-ES/ENG-IN_Ak | 31/08/2016

11 Internal | DGS-ES/ENG-IN_Ak | 31/08/2016

9 Reduced power consumption < 20mA (for standard sensor)

SOP : 2014 Mounting Location

100 200 300 400 500 600

13 Internal | DGS-ES/ENG-IN_Ak | 31/08/2016

Measures the mass(kg/hr) & temperature of Intake air.

Facts and Figures Mounting Location

SOP(pilot): 12/2017 After Air Filter in the AIS

14 Internal | DGS-ES/ENG-IN_Ak | 31/08/2016

Robust measurement of air mass flow

SOP : 2002 Mounting Location

On Engine block near cylinders

16 Internal | DGS-ES/ENG-IN_Ak | 31/08/2016

piezo effect Characteristic curve U = f ( f )

a Q/C = U excitation by acceleration 0 5 10 15 20 kHz

SOP(India): 2011 Mounting Location

On Engine block for air cooled engines

18 Internal | DGS-ES/ENG-IN_Ak | 31/08/2016

principle circuit diagram 100000

- Electrical resistance changes with temperature (thermistor)

19 Internal | DGS-ES/ENG-IN_Ak | 31/08/2016

2-wire Variable Reluctance principle

SOP : 1993 Mounting Location

20 Internal | DGS-ES/ENG-IN_Ak | 31/08/2016

Function principle Signal generation

Output versus speed Signal with a 60-2 target

21 Internal | DGS-ES/ENG-IN_Ak | 31/08/2016

Facts and Figures

SOP : 2008 Mounting Location

On Crank Wheel/fly wheel

22 Internal | DGS-ES/ENG-IN_Ak | 31/08/2016

23 Internal | DGS-ES/ENG-IN_Ak | 31/08/2016

Facts and Figures

24 Internal | DGS-ES/ENG-IN_Ak | 31/08/2016

Target wheel profile

Air gap range up to 2 mm (blind hole)

25 Internal | DGS-ES/ENG-IN_Ak | 31/08/2016

26 Internal | DGS-ES/ENG-IN_Ak | 31/08/2016