Automotive Testing Expo Europe 2011

Effectively Using Pressure

Sensors with Todays Data
Acquisition Systems
Chris Novak
Global Application Engineer
Honeywell Sensing and Control
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Electromechanical Transducer
Mechanical Input ( Force )

Wheatstone Bridge

Structure (L/L)
Electrical Output (Vout)
Strain Gage / Piezo Resistors

------------------Amplifier

Electrical Output (R/R)

Display / Output

Basic Theory

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Understanding Pressure Sensors

Pressure is defined as force per unit area
All pressure sensors use a force-summing device to convert the pressure into
a stress or displacement proportional to the pressure
The stress or displacement is then applied to an electrical transduction
element to generate the required signal
Below examples are generally related to Silicon Piezo Resistive Pressure

Pressure
(Force/Area)

Deformation of
Sense Element

Change in
Electrical
Properties

Change in
Output

Examples
RB-R

RB+R

RB+R

RB-R

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Understanding Piezo Resistive-Type Pressure

In Piezo Resistive Pressure Sensors, the transduction elements which convert
the stress from the diaphragm deflection into an electrical signal are Piezo
Resistors
Piezo Resistance = changing electrical resistance due to mechanical stress
As shown here, typically 4 Piezo Resistors are used - connected in a
Wheatstone bridge circuit - to provide an output which changes primarily with
pressure.

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Understanding Foil-Based Pressure Sensors

Two basic types of Foil-based Pressure sensors
Diaphragm
Force Sensor-based

Mechanical
Transmitter

Strain Gages
Strain Gages
Single Diaphragm

Gaged
Element
Single Diaphragm
Pressure Port

Pipe
Fluid Under Pressure
Fluid Under Pressure

Gaged Diaphragm

Gaged Force Sensor with Mechanical Transmitter

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Understanding Load Measurement

As Applied to Pressure Sensors
Load Cells Measure Direct Force
Strain Gage Technology a Key Function of Load Cells
The Structure (Spring Element) is the Most Critical Component
Multiple-bending Beam Design

Multiple-Bending Beam

Shear-Web Design

Shear Web

Strain Gage
(Wheatstone Bridge or Electrical Circuits)

Low capacity: 20 20K N

p

Capacity:
2K 1M N
p
y

P
C
T

T
C

T
C

C
T

Vout

C
T

Vin

4 active arms with pairs

subjected to equal and
opposite strains.

4 active arms with pairs

subjected to equal and
opposite strains.

A Direct Measurement of Force

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Wheatstone Bridge (Electrical Circuits)

Resistan

where

Ohms

The gage measures resistance (i.e. Ohms), which is converted to strain

when a Force is applied.
L R

Strain
R
L
Gage Factor is the ratio of resistance change to strain change. A
specific R in the gage = specific L on the base material.
+ increased resistance = increased output

R R
Gage _ Factor F R R
R RF
L

L
Vout

Vin

Vout VB VD

- Decreased resistance = increased output

Mechanical Meets Electrical

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Types of Pressure Sensors

Pressure Measurement Types

Barometric

Inches Water

Psi of Vacuum

Todays Atmospheric Pressure

Atmospheric Pressure on
day gage was sealed

Applied
Pressure

Differential
Applied
Pressure
P1

Silicon
Examples

Sealed
Reference
Applied
Pressure

Reference
Pressure

Applied
Pressure

Vacuum

True Gage

Gage

Absolute

Pressure

Gauge
(gage)

Ambient
Pressure

Differential
Pressure

Absolute

Applied
Pressure
P2

Front/Topside sensing

Absolute Vacuum
Back-side
sensing

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Typical Applications For Automotive Pressure

Assembly &
Testing

Component
Testing

Powertrain
Testing

Automated paint
system pressure
Automated sealant
dispensing systems
End of line leak testing
Oil pump testing
Cold engine testing
Fuel injection system
pressure
Vehicle fluid fill control
pressures

Fluid pump pressure

Brake system &
assembly testing
Tire manufacturing
mold pressure control
Air bag system
Suspension pressure
Hydraulic pressure

Dynamometer hot
engine testing
Oil pressure
Coolant pressure
Fuel flow,
consumption, flow &
pressure
Intake air flow
Manifold vacuum
testing
Transmission pressure
testing
Emissions testing
Cylinder compression
(cold test)

Vehicle &
Proving
Ground Testing
Road handling
(steering system
pressures)
Brake testing
(pressure)
Ride

Motorsports
Applications
Brake system status
Fuel line pressure
Aero-dynamics testing
Tire pressure
Engine diagnostics
Vacuum pressure
Fuel-air ratio

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Pressure Case Studies

PRESSURE Application 1:
Component leak test stations
End of Line stations that monitor
pressure drops on brake
cylinders, after system has been
pressurized
Model/Models:
Model Z, TJE & STJE pressure
sensor family
Accuracy & Repeatability: 0.25%,
0.1% & 0.05%
Why Use Honeywell?
Foil based sensing technology,
along with beam element design,
provides a superior temperature
performance
Hermetically sealed sensor
Flexibility of standard outputs
Compound range availability

PRESSURE Application 2:
On-board testing of transmission
fluid pressure
Pressure sensors are installed
directly on the transmission of a
test vehicle to capture actual road
performance
Model/Models:
Model S, A-105, A-205
Subminiature pressure sensors
Accuracy: 0.5% FS
Why Use Honeywell?
Foil based sensing technology
provides a superior temperature
performance
High performance with dynamically
changing temperature
On-board vehicle testing demands
small sensor package
40 years of Pedigree reliable,
stable & robust product

PRESSURE Application 3:
Automotive Brake component cycle life
testing
Monitoring brake pressure during cycle
testing to ensure accurate control
Model/Models:
Model Z, TJE & STJE pressure sensor
family
Accuracy & Repeatability: 0.25%, 0.1%
& 0.05%
Why Use Honeywell?
Better accuracy
Hermetically sealed sensor
Customizable to facilitate a bleed screw
on the pressure port, ensuring safe
return of brake fluid to reservoir

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Working with Instrumentation

Honeywell Sensors
Instrumentation

SW

1.

Sensor

mV/V

SC + A/D

D*

Bridge-based
Pressure
sensors

SW

2.

Sensor + SC

A* = 5 VDC, 10 VDC, 4-20mA

D* = Digital signal

A*

A/D

D*

SC = Signal Conditioning
A/D = Analog to Digital Conversion
SW = Software Including PC

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Plug and Play

Transducer Electronic Data Sheet (TEDS):
IEEE 1451.4 covers communication protocol
Data stored in EPROM on Sensor
Standard Templates
Accuracy options look up tables, curve fitting, etc.

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For More Information

If you would like more information on any of Honeywells
pressure transducers or other products for test &
measurement applications, please contact us:
Ph: (800) 848-6564 (U.S.) or +1 614-850-5000
Fax: +1 614-850-1111
Email: info.tm@honeywell.com
Visit Us Online: http://measurementsensors.honeywell.com

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