Articles | Volume 8, issue 1
https://doi.org/10.5194/jsss-8-75-2019
© Author(s) 2019. This work is distributed under
the Creative Commons Attribution 4.0 License.
the Creative Commons Attribution 4.0 License.
Special issue:
https://doi.org/10.5194/jsss-8-75-2019
© Author(s) 2019. This work is distributed under
the Creative Commons Attribution 4.0 License.
the Creative Commons Attribution 4.0 License.
Cylinder pressure sensors for smart combustion control
Dennis Vollberg
CORRESPONDING AUTHOR
Sensors and Thin Films Group, University of Applied Sciences,
Goebenstraße 40, 66117 Saarbrücken, Germany
Zentrum für Mechatronik und Automatisierungstechnik – ZeMA gGmbH,
Eschberger Weg 46, 66121 Saarbrücken, Germany
Dennis Wachter
Sensors and Thin Films Group, University of Applied Sciences,
Goebenstraße 40, 66117 Saarbrücken, Germany
Zentrum für Mechatronik und Automatisierungstechnik – ZeMA gGmbH,
Eschberger Weg 46, 66121 Saarbrücken, Germany
Thomas Kuberczyk
Sensors and Thin Films Group, University of Applied Sciences,
Goebenstraße 40, 66117 Saarbrücken, Germany
Günter Schultes
Sensors and Thin Films Group, University of Applied Sciences,
Goebenstraße 40, 66117 Saarbrücken, Germany
Zentrum für Mechatronik und Automatisierungstechnik – ZeMA gGmbH,
Eschberger Weg 46, 66121 Saarbrücken, Germany
Related authors
Dennis Vollberg, Peter Gibson, Günter Schultes, Hans-Werner Groh, and Thomas Heinze
J. Sens. Sens. Syst., 11, 1–13, https://doi.org/10.5194/jsss-11-1-2022, https://doi.org/10.5194/jsss-11-1-2022, 2022
Short summary
Short summary
We developed a smart in-cylinder pressure sensor for closed-loop combustion control. The sensor concept is based on a robust and reliable steel membrane equipped with highly strain-sensitive and temperature-stable thin films. The sensor system is complemented by a smart electronics allowing real-time data processing for calculation of different combustion parameters. The data are utilized to control the igniting timing of a spark plug for efficient operation of a combustion engine.
Maximilian Mathis, Dennis Vollberg, Matthäus Langosch, Dirk Göttel, Angela Lellig, and Günter Schultes
J. Sens. Sens. Syst., 10, 53–61, https://doi.org/10.5194/jsss-10-53-2021, https://doi.org/10.5194/jsss-10-53-2021, 2021
Short summary
Short summary
NiCr-carbon thin-film strain gauges offer the outstanding characteristic of a very high strain sensitivity. This can be very advantageous for many high-precision mechanical sensors like load cells. A downside of sensors based on these NiCr-carbon strain gauges is a rather large creep error, meaning reversible signal deviations at a constant load. We present two applicable methods for adjustment of the creep error: a modification of the film composition and a modification of the strain transfer.
Maximilian Mathis, Dennis Vollberg, Matthäus Langosch, Dirk Göttel, Angela Lellig, and Günter Schultes
J. Sens. Sens. Syst., 9, 219–226, https://doi.org/10.5194/jsss-9-219-2020, https://doi.org/10.5194/jsss-9-219-2020, 2020
Short summary
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This paper introduces a new method to drastically reduce the anisotropic strain sensitivity of granular thin film strain gauges. As a result, these improved strain gauges produce a much higher sensor signal when used for force transducers with biaxial strain fields. This gauge type is also more advantageous for uniaxial stress measurements. The method is based on the creation of a certain topographic structure of the strain gauges; in our case, this was realized by a picosecond laser system.
Günter Schultes, Mario Cerino, Angela Lellig, and Marcus Koch
J. Sens. Sens. Syst., 11, 137–147, https://doi.org/10.5194/jsss-11-137-2022, https://doi.org/10.5194/jsss-11-137-2022, 2022
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We develop sensor material to effectively transform mechanical force or torque into an electrical resistance. A new type of thin films containing nickel and carbon has a significantly higher output and is thus very advantageous. But so far, the electrical resistance lacks stability. We therefore investigate how to stabilize the material and show that the partial replacement of nickel by the element chromium solves the problem. The optimized sensor films are now suitable for widespread use.
Dennis Vollberg, Peter Gibson, Günter Schultes, Hans-Werner Groh, and Thomas Heinze
J. Sens. Sens. Syst., 11, 1–13, https://doi.org/10.5194/jsss-11-1-2022, https://doi.org/10.5194/jsss-11-1-2022, 2022
Short summary
Short summary
We developed a smart in-cylinder pressure sensor for closed-loop combustion control. The sensor concept is based on a robust and reliable steel membrane equipped with highly strain-sensitive and temperature-stable thin films. The sensor system is complemented by a smart electronics allowing real-time data processing for calculation of different combustion parameters. The data are utilized to control the igniting timing of a spark plug for efficient operation of a combustion engine.
Maximilian Mathis, Dennis Vollberg, Matthäus Langosch, Dirk Göttel, Angela Lellig, and Günter Schultes
J. Sens. Sens. Syst., 10, 53–61, https://doi.org/10.5194/jsss-10-53-2021, https://doi.org/10.5194/jsss-10-53-2021, 2021
Short summary
Short summary
NiCr-carbon thin-film strain gauges offer the outstanding characteristic of a very high strain sensitivity. This can be very advantageous for many high-precision mechanical sensors like load cells. A downside of sensors based on these NiCr-carbon strain gauges is a rather large creep error, meaning reversible signal deviations at a constant load. We present two applicable methods for adjustment of the creep error: a modification of the film composition and a modification of the strain transfer.
Maximilian Mathis, Dennis Vollberg, Matthäus Langosch, Dirk Göttel, Angela Lellig, and Günter Schultes
J. Sens. Sens. Syst., 9, 219–226, https://doi.org/10.5194/jsss-9-219-2020, https://doi.org/10.5194/jsss-9-219-2020, 2020
Short summary
Short summary
This paper introduces a new method to drastically reduce the anisotropic strain sensitivity of granular thin film strain gauges. As a result, these improved strain gauges produce a much higher sensor signal when used for force transducers with biaxial strain fields. This gauge type is also more advantageous for uniaxial stress measurements. The method is based on the creation of a certain topographic structure of the strain gauges; in our case, this was realized by a picosecond laser system.
Silvan Schwebke, Ulf Werner, and Günter Schultes
J. Sens. Sens. Syst., 7, 69–78, https://doi.org/10.5194/jsss-7-69-2018, https://doi.org/10.5194/jsss-7-69-2018, 2018
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Nickel–Carbon thin films are excellent materials for strain and pressure sensors: they have a sensitivity much higher than conventional metal films and have tunable resistance–temperature characteristics. We investigate the electron conduction mechanisms that lead to their large sensitivity through modeling and numerical simulations. Transverse sensitivity is explained. It is shown in agreement with experiments that the largest sensitivity occurs for a specific nickel/carbon concentration.
Günter Schultes, Hanna Schmid-Engel, Silvan Schwebke, and Ulf Werner
J. Sens. Sens. Syst., 7, 1–11, https://doi.org/10.5194/jsss-7-1-2018, https://doi.org/10.5194/jsss-7-1-2018, 2018
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This research is about future sensor devices for force, pressure, and weight. The core of such sensors for mechanical quantities is a thin film that reacts to deformation. We are developing new sensor films with higher output. Different compositions of metal containing carbon films are examined. Most preferable and stable films contain nickel and carbon. The microscopic film morphology is uncovered. Electron tunneling between nanoparticles is responsible for the very sensitive reaction.
Related subject area
Sensor principles and phenomena: Mechanical and inertial sensors
Telemetric angle and position sensing using millimeter-wave metamaterial and a frequency-modulated continuous-wave (FMCW) chip
Measurement uncertainty analysis of a measurement flexure hinge in a torque standard machine
Creep adjustment of strain gauges based on granular NiCr-carbon thin films
A tactile sensor based on magneto-sensitive elastomer to determine the position of an indentation
Novel method to reduce the transverse sensitivity of granular thin film strain gauges by modification of strain transfer
Multi-parameter sensing using thickness shear mode (TSM) resonators – a feasibility analysis
Flexible piezoresistive sensor matrix based on a carbon nanotube PDMS composite for dynamic pressure distribution measurement
Static behavior of weighing cells
Measuring the wheel-rail forces of a roller coaster
Frequency response and self-noise of the MET hydrophone
3-D-printed smart screw: functionalization during additive fabrication
Employing electro-mechanical analogies for co-resonantly coupled cantilever sensors
Offset stable piezoresistive high-temperature pressure sensors based on silicon
Silicon micro-levers and a multilayer graphene membrane studied via laser photoacoustic detection
Thin film sensors for measuring small forces
Capacitive strain gauges on flexible polymer substrates for wireless, intelligent systems
Ultrasound-based density determination via buffer rod techniques: a review
Driving modes and material stability of a double membrane rheometer and density sensor
Compensation method in sensor technology: a system-based description
Alexander Schossmann, Michael Töfferl, Christoph Schmidt, and Alexander Bergmann
J. Sens. Sens. Syst., 13, 31–39, https://doi.org/10.5194/jsss-13-31-2024, https://doi.org/10.5194/jsss-13-31-2024, 2024
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We present a concept for angle and position measurement based on metamaterials. The distance between the sensor and the rotating or moving metamaterial target is not limited to a precise value. We use state-of-the-art millimeter wave radar chip technology for read-out, initially intended for applications such as gesture recognition or contactless switches. We implement a demonstrator test setup and show the proof of principle.
Kai Geva, Holger Kahmann, Christian Schlegel, and Rolf Kumme
J. Sens. Sens. Syst., 11, 201–209, https://doi.org/10.5194/jsss-11-201-2022, https://doi.org/10.5194/jsss-11-201-2022, 2022
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The measurement principle shows how to measure calibration torque moment shunts in a 5 MN m torque standard machine using an interferometer and hinge flexure stiffness. The analysis of the measurement uncertainty influences shows that the measurement uncertainty of transversal force measurement ranges from 0.61 % to 3.04 % and stays constant at 1.7 % for torque measurement. A FE validation was performed. The measurement uncertainty of the calibration torque moment sank from 0.106 % to 0.100 %.
Maximilian Mathis, Dennis Vollberg, Matthäus Langosch, Dirk Göttel, Angela Lellig, and Günter Schultes
J. Sens. Sens. Syst., 10, 53–61, https://doi.org/10.5194/jsss-10-53-2021, https://doi.org/10.5194/jsss-10-53-2021, 2021
Short summary
Short summary
NiCr-carbon thin-film strain gauges offer the outstanding characteristic of a very high strain sensitivity. This can be very advantageous for many high-precision mechanical sensors like load cells. A downside of sensors based on these NiCr-carbon strain gauges is a rather large creep error, meaning reversible signal deviations at a constant load. We present two applicable methods for adjustment of the creep error: a modification of the film composition and a modification of the strain transfer.
Simon Gast and Klaus Zimmermann
J. Sens. Sens. Syst., 9, 319–326, https://doi.org/10.5194/jsss-9-319-2020, https://doi.org/10.5194/jsss-9-319-2020, 2020
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In this paper, we present a tactile sensor based on the interaction of coils with a magnetic elastomer. The first experimental approach is sampling the sensor with indentations of constant depth at different positions. A mathematical model is used to reproduce the data. Afterwards, this model is applied to random indentations at the same depth. As a result, we provide conceptual proof for position determination in one direction as a basis for a refined sensor design and further model approaches.
Maximilian Mathis, Dennis Vollberg, Matthäus Langosch, Dirk Göttel, Angela Lellig, and Günter Schultes
J. Sens. Sens. Syst., 9, 219–226, https://doi.org/10.5194/jsss-9-219-2020, https://doi.org/10.5194/jsss-9-219-2020, 2020
Short summary
Short summary
This paper introduces a new method to drastically reduce the anisotropic strain sensitivity of granular thin film strain gauges. As a result, these improved strain gauges produce a much higher sensor signal when used for force transducers with biaxial strain fields. This gauge type is also more advantageous for uniaxial stress measurements. The method is based on the creation of a certain topographic structure of the strain gauges; in our case, this was realized by a picosecond laser system.
Manfred Weihnacht
J. Sens. Sens. Syst., 8, 133–147, https://doi.org/10.5194/jsss-8-133-2019, https://doi.org/10.5194/jsss-8-133-2019, 2019
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Multi-parameter sensing is examined for thickness shear mode resonators that are in mechanical contact with thin films and half-spaces on both sides. A formula is derived that delivers insight into a set of material and geometry parameters accessible by measurement. Further analysis addresses the problem of accuracy of extracted parameters at a given experimental uncertainty. The demonstrated procedure is suitable for developing experimental strategy for highly efficient multi-parameter sensing.
Rajarajan Ramalingame, Zheng Hu, Carina Gerlach, Dhivakar Rajendran, Tatiana Zubkova, Reinhard Baumann, and Olfa Kanoun
J. Sens. Sens. Syst., 8, 1–7, https://doi.org/10.5194/jsss-8-1-2019, https://doi.org/10.5194/jsss-8-1-2019, 2019
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An advanced-material-based thin, flexible sensor mat has been synthesized to record and visualize both the position and pressure of applied load. Such a pressure measurement system bears great potential in human health monitoring applications like long-term patient monitoring mattresses or insoles for gait monitoring.
Maximilian Darnieder, Markus Pabst, Ronny Wenig, Lena Zentner, René Theska, and Thomas Fröhlich
J. Sens. Sens. Syst., 7, 587–600, https://doi.org/10.5194/jsss-7-587-2018, https://doi.org/10.5194/jsss-7-587-2018, 2018
Andreas Simonis and Christian Schindler
J. Sens. Sens. Syst., 7, 469–479, https://doi.org/10.5194/jsss-7-469-2018, https://doi.org/10.5194/jsss-7-469-2018, 2018
Dmitry L. Zaitsev, Svetlana Y. Avdyukhina, Maksim A. Ryzhkov, Iliya Evseev, Egor V. Egorov, and Vadim M. Agafonov
J. Sens. Sens. Syst., 7, 443–452, https://doi.org/10.5194/jsss-7-443-2018, https://doi.org/10.5194/jsss-7-443-2018, 2018
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An electrochemical hydrophone based on the principles of molecular electronic transfer (MET) is described. The paper presents theoretical and experimental results for the sensitivity and the level of self-noise determination for METH in the frequency range of 0.02–200 Hz, which determines the fields of acceptance of the devices being developed. An experimental model has been developed by using a force-balancing feedback. Different methods and techniques for its calibration have been developed.
Daniel Gräbner, Simon Dödtmann, Gerrit Dumstorff, and Frieder Lucklum
J. Sens. Sens. Syst., 7, 143–151, https://doi.org/10.5194/jsss-7-143-2018, https://doi.org/10.5194/jsss-7-143-2018, 2018
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We combine two modern trends in component fabrication, namely, the integration of sensors into machine parts and the 3-D-printing technology, which is rapidly emerging in the fabrication of standardized and customized components and prototypes. We present a 3-D-printed ‘smart’ screw with an integrated strain gauge. The signal of the sensor can be used to monitor the fastening process of the screw as well as the reduction in strength of the screw joint over time.
Julia Körner, Christopher F. Reiche, Bernd Büchner, Thomas Mühl, and Gerald Gerlach
J. Sens. Sens. Syst., 5, 245–259, https://doi.org/10.5194/jsss-5-245-2016, https://doi.org/10.5194/jsss-5-245-2016, 2016
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The presented work gives insight into the behaviour of co-resonantly coupled oscillating cantilever beams by means of electro-mechanical analogies. An electric circuit model is analysed with various stages of complexity, and conclusions are drawn regarding the applicability of the co-resonant concept for sensors. Furthermore, this is validated by a comparison between the theoretical predictions and experimental data.
Robert Täschner, Erik Hiller, and Michael Blech
J. Sens. Sens. Syst., 5, 197–203, https://doi.org/10.5194/jsss-5-197-2016, https://doi.org/10.5194/jsss-5-197-2016, 2016
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The exploitation of new application fields and the drive to size reduction even in highly stable pressure sensing systems makes the extension of the operating temperature range of the microelectromechanical sensors (MEMS) essential. For this reason, a silicon-based pressure sensor with an application temperature ranging up to 300 °C and the associated manufacturing technology was developed. The evolved sensor has an excellent stability and is uncomplicated to mount due to its stress insensitivity.
Z. Zelinger, P. Janda, J. Suchánek, M. Dostál, P. Kubát, V. Nevrlý, P. Bitala, and S. Civiš
J. Sens. Sens. Syst., 4, 103–109, https://doi.org/10.5194/jsss-4-103-2015, https://doi.org/10.5194/jsss-4-103-2015, 2015
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We tested two types of home-made sensing elements – four coupled silicon micro-levers and a multilayer graphene membrane – which have the potential to further enhance the sensitivity of laser photoacoustic spectroscopy. Graphene sheets possess outstanding electromechanical properties and demonstrate impressive sensitivity as mass detectors. Their mechanical properties make them suitable for use as micro-/nano-levers or membranes, which could function as extremely sensitive pressure sensors.
F. Schmaljohann, D. Hagedorn, and F. Löffler
J. Sens. Sens. Syst., 4, 91–95, https://doi.org/10.5194/jsss-4-91-2015, https://doi.org/10.5194/jsss-4-91-2015, 2015
R. Zeiser, T. Fellner, and J. Wilde
J. Sens. Sens. Syst., 3, 77–86, https://doi.org/10.5194/jsss-3-77-2014, https://doi.org/10.5194/jsss-3-77-2014, 2014
S. Hoche, M. A. Hussein, and T. Becker
J. Sens. Sens. Syst., 2, 103–125, https://doi.org/10.5194/jsss-2-103-2013, https://doi.org/10.5194/jsss-2-103-2013, 2013
B. Weiss, M. Heinisch, E. K. Reichel, and B. Jakoby
J. Sens. Sens. Syst., 2, 19–26, https://doi.org/10.5194/jsss-2-19-2013, https://doi.org/10.5194/jsss-2-19-2013, 2013
V. Schulz, G. Gerlach, and K. Röbenack
J. Sens. Sens. Syst., 1, 5–27, https://doi.org/10.5194/jsss-1-5-2012, https://doi.org/10.5194/jsss-1-5-2012, 2012
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Short summary
The basis of our work presented in this paper stems from the research on new materials, especially temperature-stable thin films that transform strain into a resistance change very effectively, allowing higher sensitivity and higher operating temperatures. Different sensor concepts for time-resolved cylinder pressure monitoring of combustion engines are realized and evaluated. Reliable sensors with a minimum of internal components are provided.
The basis of our work presented in this paper stems from the research on new materials,...
Special issue