Sensor Technology

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Sensor Technology
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AUTOMOT I VAT E D I N EVERY D E TA I L
Our global automotive research centers are setting the technological
landscape by developing new technologies, products and production
processes. The increasingly fast growing number of functions in present
and future cars require varieties of powerful and versatile connection
systems. We compare existing standards with alternative possibilities
in which costs, functionality, dependability and serial production are
the basics of our procedures.
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T E C H N O LO GY
Tyco Electronics has focused on contactless sensors solutions special for high
performing and sophisticated measurement tasks. Wear influences as well as
mechanical interactions between sensor and application parts are then avoided.
Beside the actual measurement requirements, the application conditions
determine the choice of the appropriate sensor technology. For contactless
measurements preferably magnetic sensor technologies are used:
Semi-conductor sensors with integrated Hall
Semi-conductor sensors with MR elements
Magneto-inductive PLCD sensors
Temperature sensor devices
Table (p.4) compares the characteristic application profile of these important
sensor technologies. Semi-conductor solutions with Hall and MR effect show
their advantages in their very compact and slim design. They are also
preferred in the design of complex sensor clusters. The combination with
different magnet configurations, typical integrated or moving magnets
obtains precise measurement results.
A very efficient and robust sensor technology is the Tyco Electronics
patented PLCD (Permanentmagnetic Linear Contactless Displacement
Sensor) Technology. For the linear position measurements this principle
has various advantages. The magnetic-inductive measuring principle
distinguishes for its very large operation tolerance field. This enables
the renunciation for specially guided or stored slider and records
reliably its highly precise measuring performance without any loss,
not being influenced by metal abrasions. The necessary driving
magnet can herewith be fixed directly on the setting element,
whereas even driving distances through non-ferromagnetic walls
with several millimetre thickness, are not an exclusion criteria for this
measuring principle. A fully enclosed design guarantees the robustness
of this measuring principle. Therefore the encapsulated sensor is
completely sealed and temperature resistant up to 160 C.
Door Locking Unit with
integrated Hall-Devices
PLCD Gear & Shift travel
sensor for Automated
Manual Transmission
C O M P E T E N C I E S
Tyco Electronics, as sensor manufacturer and development partner, utilizes its
experience to provide customer support on project work of new sensor
applications. Once the application has been analyzed, the suitable sensor
technology is selected and the corresponding mechanical, electrical and
magnetic interfaces are defined.
The design of the magnetic interface in particular requires a close cooperation
with the customer. Special attention is paid to the external influencing factors
of the applications.
During the design of the magnetic circuits, analytical and empirical methods
are used which take into account the magnetic polarization angle-error and
the surrounding magnet field influences. State-of-the-art procedures, involving
FEM calculations, are used to analyse or design magnetic circuits. Based on
the results of these calculations, the properties of the magnet arrangement
will be verified and optimised through prototype testing.
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FEM calculation for dimensioning the
magnetic sensor interface
Specific integrated electronic units ensure reliable signal conditioning and
implementation of additional functions such as advanced signal evaluations,
generation of control signals and complex diagnostic features. The electronic
functions are designed with efficient ASIC technologies.
The selection of materials is determined by technical constructive requirements
as well as on the environmental conditions. The wide temperature-load profile,
high vibration strains and many different chemical liquids define the requirements
regarding robustness and sealing of the respective sensor technology. The
product architecture is defined by the application space requirements and the
required connector or pigtail requirements. For hermetic and oil-tight sealing
the sensor housings are molded without blowholes and closed with
laser-welded housing covers.
Extensive component tests and life tests under application conditions provide
the proof for a reliable and durable sensor design.
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PROJECT PLANNING AND ASSISTANCE
As sensor manufacturer and processing partner, Tyco Electronics also
provides project planning support for new sensor applications, assistance
in the selection of the appropriate sensor technology for the respective
application, and assistance with defining the corresponding mechanical,
electrical and magnetic interface.
Digital and linear position
measurement for clutch
master cylinder
PLCD sensor module for gear
and shift measurement
A P P L I C AT I O N S
Tyco Electronics offers a comprehensive portfolio of sensors for the automotive
industry, including switching, travel, rotational, speed and temperature. The
primary focus is on contactless technologies to ensure a high level measuring
performance, longterm reliability, and the elimination of interference effects
and wear and tear.
Tyco Electronics is the leading supplier for contactless sensors for hydraulic,
pneumatic and electro-mechanical actuators used on cars, trucks and busses.
Typical applications are:
Automated Transmission and Clutch Systems
Turbocharger, Throttle, Exhaust Gas Recirculation (EGR), Manifold Intake
Generator, Alternator
Electrical Powered Assisted Steering (EPAS)
Convertibles
In addition to the controlled actuator segment, Tyco Electronics also offers a
wide range of innovative and cost-effective sensor solutions for following
applications:
Seat Sensors (track position, occupant weight, buckle)
Clutch- and Brake Pedal Switches
ABS Wheel Speed
Cam- and Crankshaft
Transmission Gear Wheels
Chassis Level
Door- and Tailgate Latches
Outer Air Temperature
Fuel Level