Continuous Acquisition of Measuring Data up to an Enviromental Temperature of 180 C (Temperature, Deformation, Pressure between Piston Rings)
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1 Continuous Acquisition of Measuring Data up to an Enviromental Temperature of 180 C (Temperature, Deformation, Pressure between Piston Rings) Dr. Ernst Manner Manner Sensortelemetrie Spaichingen, Eschenwasen 20 Content - nline acquisition of the surface at a piston with spot mode - nline high dynamic acquisition of the surface at a piston - nline acquisition of the at the bearing of a connecting rod - High dynamic multi channel load analysis of the connecting rod File: f:\...\mtrmesstechnik_en.cdr //
2 Who we are? * Spezialized company for contactless measuring signal transmission without batteries at rough environment * More than ten years of experience Hamburg Hannover Leverkusen Cologne Berlin * Patented transmission technique Frankfurt Nuremberg Stuttgart Spaichingen Munich Spaichingen Eschenwasen 20 Telefon: Fax: manner@sensortelemetrie.de Internet: ( about. 90 km south of Stuttgart, near Lake Constance motorway)
3 How does Sensor Telemetry work? Patented Energy and Data Transmission (Stator <--> Rotor) HF frequency 13,56 MHz Sensor Signal Amplifier Power supply Demodulator Demodulator Modulator Stator antenna Rotor loop Digitizer Digital absorption modulation Receiver Stationary Energy RMC Data / Cal Measuring data Sensor signal amplifier Shaft Rotating
4 Measuring Mission at the Engine ptimation of automotives (engine, gear) by measuring the load at moving parts Temperature at the surface of the piston Dynamic forces at the timing chain Pressure between piston rings Dynamic distance between piston and cylinder Forces at the shoulder bearing of the connecting rod Bearing Load at the crankshaft
5 Multi Channel Temperature Measurement at the Surface of a Piston Requirements: * Enviromental up to 175 C * nly small modifications at engine components * No feedback * Mechanical strength up to 10,000 rpm * High signal accuracy * Low weight and small size of the measuring technique * Simple mounting * Low mechanical requirement * Unlimited measuring life (without batteries) Signal amplifier Measurement arrangement
6 State of the Art: Measurement with a motion link Drawbacks: * Feedback to the process * High mechanical requirements * Parting of the cable * Limited measuring time Signal amplifier Measurement with moving coil (method of Essert) NTC Drawbacks: * Feedback to the process * Signal accuracy * High expenditure * High mechanical requirements * Problem with size Signal amplifier
7 Acquisition of the Surface Temperature at a Piston up to 180 C Ambient Temperature (Spot Measuring Mode, Digital Transmission Technique) Applicated Piston with thermocouples type NiCr.-Ni Thermocouple 8 channel rotor electronic Rotor antenna Receiving antenna Evaluation Unit Contactless energy and data coupling via crankshaft segment 8 channel sensor signal amplifier Weight 3 g 5,5
8 Signal Transmission Rotational speed = 7000 rpm Sampling process per channel Phi Piston stroke 85 mm Receiving antenna Piston stroke 116 Piston stroke = ca.85 mm 20 t 20 Power supply Contact angle Active hight of the antenna Calculating the Contact Angle Phi: Piston stroke/2-active hight of antenna Phi = 2*arcos ( ) Piston stroke/2 = 2 *arcos 22,5 42,5 = 2 * 58,03 = 116,07 Calculating the Contact Time: Contact time = 1(rpm/60)* Phi/360 = = 2,76 ms at 7000 rpm Transmission time for measuring data: 2,5 ms Codition: Contact time > Transmission time: ok Signal contact on Start channel1 Channel multiplexer Sensor Signal Amplifier multiplexed signal (electrical) Adress unit receiver Temperature signal channel 1 (at the telemetry output) t1 t2 t k Channel multiplex time t k = 250 µs RisetimeT=t1+t2+tk=1ms t t t t t t
9 Function Sequence of the acquisition of the measuring signal Measuring channel x Data transmission Sensor 1 Sensor 2 Telemetry measuring amplifier Piston stroke No. t Block Diagram 8 7 Receiver Demultiplexer Build-up 1... Sensor 3 Sensor 15 Multiplexer Amplifier Logic +1 HF Stage HF Stage Demodulator Address unitt RS232 Interface Amplifier channel 1 with S&H.. Amplifier channel 8 with S&H 8 16 Bit integer To the PC
10 8 Channel Piston Telemetry (max. ambient =180 C) Application: nline measurement of the temperatur profil at the piston Evaluation unit Piston Rotor antenna Technical data: Number of channels (total): 8 Usable channels: 6 (expandable up to 32 channels) 1 channel for cold junction 1 channel for zero point drift Measuring range: -40 to +550 C Sensor: Thermocouple NiCr-Ni Integrated power supply Mode: 1 measurement per piston stroke utput signal: 0 to +10 V, (optional RS232) Enviromental : -40 to +180 C max.) Size: 21 x 10 x 5,5 mm Max. acceleration: g Weight: 3 g Thermocouple 8 channel rotor electronic Rotor antenna Receiving antenna 5,5 8 channel sensor signal amplifier weight 3 g
11 Transmission Technology Variant 1 Variant 2 with linear coupler with moving coil Piston Piston Sensor signal amplifier Rotor antenna Stator antenna pickup Sensor signal amplifier Rotor antenna Stator antenna pickup
12 8-Channel online Piston Surface Temperature Acquisition (Spot Mode) with thermocouple Typ NiCr.-Ni Applicated Piston Thermo couple 8-channel rotor electronic Rotor coil Receiving antenna Contact less energy and data transmission over a shot angle Reiceiver 5,5 To receiver 8 channel sensor signal amplifier weight 3 g
13 Moving coil integrated into the piston Sensor Signal Amplifier fixed at the inner side of the piston Cable arrangement thermocouples Stator antenna (pickup) fixed at the engine unit
14 Sensor signal amplifier Applicated Piston Rotor coil Thermocouples
15 Piston of a Car Motor with mounted Sensor Telemetry Piston Mounted sensor signal amplifier Counter weight of crankshaft
16 Piston of a Car Motor with Mounted Sensor Telemetry With moving coil Piston Sensor signal amplifier Rotor antenna Stator antenna pickup
17 Piston of a Ship Motor with mounted Sensor Telemetry Piston antenna 24 channel sensor signal amplifier Thermo element wire Technical Data: Number of channels (total): 16/24/32/48 Usable channels: 8/modul (expandable up to 48 channels) 1 channel for cold junction 1 channel for zero point drift Measuring range: -40 to +550 C Sensor: Thermocouple NiCr-Ni Integrated power supply Mode: 1 measurement per piston stroke utput signal: 0 to +10 V, (optional USB, TCP/IP) Enviromental : -40 to +180 C max.) Robust metal housing size: Max. acceleration: g Weight: 15 g (dependent on channel count)
18 Measurement of the Temperature at Bearings of Conrod once per Stroke (fired Engine) Electronic Sensor signal amplifier Pickup Thermo couples Conrod antenna 8 channel sensor signal amplifier weight 3 g ,5 Technical Data: Number of channels (total): 4/8 Usable channels: 6 (expandable up to 32 channels) 1 channel for cold junction 1 channel for zero point drift Measuring range: -40 to +550 C Sensor: thermocouple NiCr-Ni Integrated power supply Mode: 1 measurement per piston stroke utput signal: 0 to +10 V, (optional TCP/IP, USB) Enviromental : -40 to +180 C max,) Size: 21 x 10 x 5,5 mm Max. acceleration: g Weight: 3 g
19 Measurement of the Temperature at Bearings of Conrod once per Stroke (fired Engine) Technical Data: Number of channels (total): 4/8 Usable channels: 6 (expandable up to 32 channels) 1 channel for cold junction 1 channel for zero point drift Measuring range: -40 to +550 C Sensor: Thermocouple NiCr-Ni Integrated power supply Mode: 1 measurement per piston stroke utput signal: 0 to +10 V, (optional TCP/IP, USB) Enviromental : -40 to +180 C max.) Size: 21 x 10 x 5,5 mm Max. acceleration: g Weight: 3 g
20 Stress Measurement Valve Shaft (Passenger Car) on test rig driven electro engine Amplifier Valve Technical Data: Number of channels: 1 dynamic strain measurement bandwith: 0 to 50 khz Sensor: strain gauges Integrated power supply utput signal: 0 to +10 V, (optional TCP/IP, USB) Enviromental : -40 to +160 C max.) Size: D=22mm,H=2,5mm Max. acceleration: g Weight: 2 g Type: Valve_L_... Test rig Load Stator antenna t
21 Valve Temperatur Measurement on Passenger Car on fired Engine R mm Movement of the sensor signal amplifier Technical Data: Number of channels: 1 Spot mode integrated cold junction Measuring range: -40 to +550 C Sensor: Thermocouple NiCr-Ni, PT100 Integrated power supply Mode: 1 measurement per piston stroke utput signal: 0 to +10 V, (optional TCP/IP, USB) Enviromental : -40 to +160 C max,) Size: D=22mm,H=6mm Max. acceleration: g Weight: 3 g Type: Valve_T_...
22 8/4/16 Channel Valve Temperature Telemetry for Ship s Engine (with thermocouples type K) max. 12 mm Technical Data: Number of channels: 1/2/4/8/16 Spot mode Integrated cold junction Measuring range: -40 to +550 C Sensor: Thermocouple NiCr-Ni, PT100 Integrated power supply Mode: 1 measurement per piston stroke utput signal: 0 to +10 V, (optional TCP/IP, USB) Enviromental : -40 to +160 C max,) Size: D=22mm,H=6mm Max. acceleration: g Weight: 20 g Type: valve_t_... USB Amplifier with transmitter Sensortelemetry Demultiplexer Demultiplexer HF - enerator HF-Leistung M A MA MA min max M A
23 Engine Telemetry for High Frequency Signal Acquisition (0 to 10 khz) in Spot Mode using Short Time Datalogger (intermitting mode)
24 Dynamic Position Movement Acquisition with Distance Sensors based on Loggtel (on piston mounted short time datalogger, without batteries) Distance sensors Piston Technical Data: Dynamic distance measurement 0 to 0,5 mm Max. length of measurement cycle: 1,5/3/6/12 sec Number of cycles: unlimited (Spotmode) Max. accelaration: 10000g Channel count: 4/8 channels Sensors: distance sensor Sampling rate: /20 000/10 000/5000 sample/sec/channel Rotational speed: 400 to 8000 RPM Enviromental : 0 to 125 C (150 C) Data acquisition via PC (TCP-IP) Integrated time stamp and trigger mark Type:DATL_... Sensor signal amplifier Rotor antenna Stator antenna pickup TCP/IP Sensortelemetry Demultiplexer Demultiplexer HF - enerator HF-Leistung M A MA MA min max M A
25 Dynamic Load Measurement with Strain auges on Piston based on Loggtel (on piston mounted short time datalogger, without batteries) Distance sensors Piston Technical Data: Dynamic strain measurement with strain gauges Max. length of measurement cycle: 1,5/3/6/12 sec Number of cycles: unlimited (Spotmode) Max. accelaration: 10000g Channel count: 4/8 channels Sensors:strain gauge/ PT100 Sampling rate: /20 000/ sample/sec/channel Rotational speed: 400 to 8000 RPM Enviromental : 0 to125 C (150 C) Data acquisition via PC (TCP-IP) Tntegrated time stamp and trigger mark Type: DATL_... Sensor signal amplifier Rotor antenna Stator antenna pickup TCP/IP 4 channel sensor signal amplifier Sensortelemetry M A Demultiplexer MA Demultiplexer MA HF - enerator HF-Leistung min max M A
26 Dynamic Load Measurement with Strain auges on Conrod based on Loggtel (on piston mounted short time datalogger, without batteries) Data logger Technical Data: Dynamic strain measurement with strain gauges Max. length of measurement cycle: 1,5/3/6/12 sec Number of cycles: unlimited (Spotmode) Max. accelaration: 10000g Channel count: 4/8 channels Sensors:strain gauge/ PT100 Sampling rate: /20 000/ sample/sec/channel Rotational speed: 400 to 8000 RPM Enviromental : 0 to 125 C (150 C) Data acquisition via PC (TCP-IP) Integrated time stamp and trigger mark Type: DATL_... Rotor antenna TCP/IP Sensortelemetry Demultiplexer Demultiplexer HF - enerator Stator antenna HF-Leistung M A MA MA min max M A
27 Dynamic Load Measurement with Strain auges on Conrod (Ship s Engine) based on Loggtel (on piston mounted short time datalogger, without batteries) Rotor antenna Technical Data: Dynamic strain measurement with strain gauges Max. length of measurement cycle: 1,5/3/6/12 sec Number of cycles: unlimited (Spotmode) Max. accelaration 10000g Channel count: 4/8 channels Sensors:strain gauge/ PT100 Sampling rate: /20 000/ sample/sec/channel Rotational speed 400 to 8000 RPM Enviromental : 0 to 125 C (150 C) Data acquisition via PC (TCP-IP) Integrated time stamp and trigger mark Type: DATL_... Sensor signal amplifier channel 1 to 4 TCP/IP Sensortelemetry Demultiplexer Demultiplexer HF - enerator HF-Leistung Receiving antenna (pickup) M A MA MA min max M A
28 Block Diagram (complete System) Position 90 to 270V AC Distance ption remote control for gain, zero with 12 bit resolution and shunt Cal. 0 to ±10V Multi channel Sensor Signal Amplifier 868 MHz Radio TCP/IP Rotor electronic Induktive support 13,56 MHz Receiver serial Piezo electrical Sensor Remote calibration PC
29 Timing Antenna Transmission mode Signal contact Supply Power Supply time t >2ms time t
30 Mode Cycles Measuring mode about 1,6 s Transmission mode Measuring mode about 1,6 s Transmission mode Sampling rate: Measuring mode: 160 ksample/s Memory size: 256 ksample Transmission mode: Transmission rate 1,67 MBit (100 ksample/s) Contact time about 10% of revolution (72 of the crankshaft) Transmission time about 2,56 s
31 Block Diagram Sensor Signal Amplifier Amplifier with filter A/D converter µp Amplifier with filter A/D converter Sensor Amplifier with filter A/D converter Memory Evaluation unit Amplifier with filter / AD converter 4 channel sensor signal amplifier
32 Spot mode: Advantage: - Simple mounting - Less application requirement Disadvantage: - nly one measurement per piston stroke Try to find a continuous measurement method with less application requirement
33 Working Mechanism Piston Rotor electronic Rotor antenna Stator antenna Rotor antenna Measuring points (Thermocouple) Sensor signal amplifier
34 Conditions of Transmission Lower dead center Upper dead center
35 Depending on the arrangement of the antennas a continuous transmission of signal data during the whole piston stroke is possible. n optimal condition of data transmission a data transfer rate of 3,5 MBit is possible Useful for Force sensors Thermocouples Distance sensors Dynamic measurement of the pressure between piston rings Dynamic measurement of the at the piston of ignition Dynamic measurment of piston displacement
36 Advantages of the Sensor Telemetry - Less requirement of mounting (only about 40%, as our cutomers told us) - High signal accuracy 0,5 C - Signal transmission free from interferences - Less modifications at engine components - Quick mounting - Low cost - Less additional weight 5 g - No feedback to the engine - Maintenance-free - High noise immunity - High resistance up to 180 C References: * MTU Friedrichshafen * Caterpillar * B&W-Diesel * Mahle * Federal Mogul * etc.
37 Solutions for further Engine Measuring Missions
38 High dynamic Multi Channel Analysis of the Load at a Conrod Requirements: * Ambient up to 150 C * nly small modifications at engine components * No feedback * Mechanical strength up to 10,000 rpm * High signal accuracy * Low weight and small size of the measuring technique * Simple mounting * Low mechanical requirements * Unlimited measuring life (without batteries) Strain gage elements Signal amplifier
39 State of the Art: Measurement with a motion link Drawbacks: * Feedback to the process * High mechanical requirements * Parting of the cable * Limited measuring time Signal amplifier
40 Measuring the Force at the Shoulder of the Connecting Rod with double Transmission (continuous data transmission) Technical Data: Number of channels: 4 Transmission: digital Resolution: 12 Bit Sampling rate: data/sec and channel Sensor: Strain gage, thermocouple Accuracy: 0,01 %/ C Temperature: max. 150 C Evaluation unit (receiver)
41 Digital multiplexer Block Diagram Sensor Signal Amplifier Piezo electrical 1 3,3 V Supply voltage strain gage bridge Remote shunt calibration Prog. amplifier 0 to 10kHz Filter butterworth A/D converter 12 Bit Simultanious sampling Converting Logic / supply Strain gage bridge Rv Converting rate 40k 13,56 MHz Strain gage bridge 2 Prog. amplifier 0 to 10kHz Filter butterworth Converting A/D converter 12 Bit Thermocouple Strain gage bridge... n 4 Rv... Prog. amplifier Rv 0 to 10kHz Filter butterworth Rv Converting rate 40k.... Converting A/D converter 12 Bit Converting rate 40k about 3,4 MBit
42 To the evaluation unit Cap piece of the bearing Stator antenna 1 (pickup) Mode of Transmission 4 channel rotor electronic Rotor antenna 2 Rotor antenna 1 Stator antenna 2 Conrod Crankshaft Sensor Rotor electronic Rotor antenna 2 Stator antenna 2 Rotor antenna 1 Stator antenna 1 Receiver
43 Conrod Strain gage Sensor signal amplifier Rotor antenna
44 Measuring Tensile Force at Chain Links Fixing Insulation 0,1 to 4 mm Stator induction loop Prepared chain link Sensor signal amplifier with integrated antenna Strain gage sensor Technical Data: Transmission principle: inductive Sensor: Strain gage (full and half) Strain gage bridge supply: 6 V Strain gage resistance: 1000 Max. signal bandwidth: 10/20 khz Energy supply: Integrated into the system Ambient : -30 to 150 Celsius Weight sensor signal amplifier (rotor electronic: 5 g) Size:20x21x7mm Signal drift: 0,01 %/ C Max. acceleration: 20,000 g Sampling in segments: possible Rise time: 500 µs Max. air gap: 4 mm To the receiving antenna Evaluation unit Rotor electronic Strain gage half bridge Evaluation unit
45 Temperature Acquisition on Clutch with Multichannel Telemetry 8-channel sensorsignal amplifier Pickup channel sensor signal amplifier Receiver Technical Data: Sensortelemetry Demultiplexer Demultiplexer M A MA MA USB Channel count : 8 (time multiplex) Sampling rate per channel: 2000 Integrated sensor amplifier Sensors: NiCr.-Ni Thermo couple, Zero point drift: 0,02 %/ C Enviromental : -25 to 180 C
46 Measuring dynamic loads on crankshaft Strain gage half bridge Rotor electronic USB, TCP/IP Evaluation unit wiring channel inside crankshaft 8 channel sensor signal amplifier radial pick up Technical Data: 8 channel sensor telemetry Sensors: strain gage (full and half), Thermocouple type K Strain gage bridge supply: 3,3 V Strain gage resistance: 350 Max. signal bandwidth: 5/10/20 khz End of shaft solution Inductive Energy supply: Ambient : -30 to 160 Celsius Weight Sensor signal amplifier (rotor electronic: 50 g) Size: Diameter 40, length: 52 mm Signal drift: 0,01 %/ C Max. acceleration: 20,000 g options RPM detection (trigger mark) remote controlled gain and zero adjustment with 12 bit resolution (autozero) Sensortelemetry Demultiplexer Demultiplexer M A MA MA Evaluation unit Type: MSV_RAH_<channels>_<accuracy>_<temp>_<mod>_<sampling rate> PCM PCM ,02 0,01 0, FM* total sampling rate
47 Turbo Charger
48 Turbo Charger Telemetry (Cylinder Form) 1 Channel FM Transmitter for dynamic strain gage Sensitivity: 0,5 mv/v to 4 mv/v Bandwidth: 10 Hz (0) Hz to 40 khz Brigde supply: 6 V Integrated filters Resolution: 12 Bits Remote shunt calibration Enviromental : -25 to 125 C (150 C) Max load: 130,000 g Transmit frequency: 300 to 750 MHz Type: MSV_P_D_2_125_FM_...
49 Car Turbo Charger Transmitter (Cylinder Form) With integrated connector 2 Channel PCM Transmitter for dynamic strain gage Sensitivity: 0,5 mv/v to 4 mv/v Bandwidth: 10 Hz (0) Hz to 50 khz Brigde supply: 5 V (3 V) Digital transmission, inductive supply (axial) Time aligned sampling Separate A/D converter Integrated filters Resolution: 12 Bits Remote shunt calibration Enviromental : -25 to 125 C (150 C) Max load: 100,000 g Transmit frequency: 300 to 750 MHz Type: MSV_P_D_2_125_Fu_...
50 Car Turbo Charger Transmitters (Cylinder Form), rpm /4 Channel PCM Transmitter for thermocouple and strain gage (torque) Sensitivity: 0,5 mv/v to 20 mv/v Bandwidth: 10 Hz (0) Hz to 1 khz Brigde supply: 3,3 V Digital transmission, inductive supply (axial) Integrated filters Resolution: 16 Bits Remote shunt calibration Enviromental : -25 to 125 C (160 C) Max speed: rpm Axial mounting on shaft Type: MSV_P_D_2_125_PCM_...
51 Car Turbo Charger Transmitters (Cylinder Form), rpm Torque Measuring at Turbo Charger Sensor signal amplifier Wiring inside the shaft Strain gages Technical Data Torque range: 0 to 1 Nm Type of sensor: strain gage Accuracy: 1% Bandwidth 0 to 1 khz Enviromental : 0 to 150 C Brigde supply: 3,3 V Digital transmission, inductive supply (axial) Integrated filters Resolution: 16 Bits Remote shunt calibration Max speed: 200,000 rpm Transmitter: axial mounting on shaft Type: MW_T_D_1_150_PCM_...
52 Industrial Turbo Charger Telemetry (1/ 4/ 8/16 channel(s) (multi channel), thermocouple) Features 4/8/16 Channel PCM Transmitter for dynamic measurements (strain gage) Minature size: D = 16 mm, L = 30 mm Sensitivity: 0,5 mv/v to 4 mv/v Bandwidth: 10 Hz (0) Hz to 50 khz Brigde supply: 3,3 V Digital transmission Integrated filters Resolution: 16 Bits Remote shunt calibration Remote controlled gain, autozero (option) Enviromental : -25 to 125 C (150 C) Max speed: 100,000 RPM Max load: 130,000 g Radio transmitting: 300 to 800 MHz Weight: 30 g Type: MSV_P_D_4_125_Fu_...
53 Digital multiplexer PCM Telemetry for Turbine / Turbo Charger Application Block diagram module (8 channel transmitter, high speed) Isochronous sampling Logic 1 Channel 1 Power supply Sampling Prog. amplifier Filter butterworth A/D converter 12 Bit Strain gage bridge Rv Remote shunt calibration 0to25(50)kHz Sampling rate 100/200k 2 Strain gage bridge Channel 2 Prog. amplifier Rv Remote shunt calibration Power supply Filter butterworth 0to25(50)kHz A/D converter 12 Bit Sampling Sampling rate 100/200k About 13 MBbit Backbone 8 Channel 8 Power supply Sampling Prog. amplifier Filter butterworth A/D converter 12 Bit Strain gage bridge Rv Remote shunt calibration 0to25(50)kHz Sampling rate 100/200k
54 Telemetry Application on an Industrial Turbo Charger Rotor electronic Rotor antenna (pickup) 16 Channel PCM Transmitter for thermocouple type K, static strain gage Range: -50 to 1,000 C Time multiplex Brigde supply: 5 V Bandwidth: 0 to 20 Hz Quasi isolated inputs 12 Bit A/D Converter Integrated filters Resolution: 12 Bits Remote shunt calibration Enviromental : -25 to 125 C (150 C) Max load: 100,000 g Transmit frequency: 300 to 750 MHz Type: MSV_M_T_16_125_Fu_...
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