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 Geramny-based Beru AG has developed distance sensors for modern turbochargers. The Ludwigsburg-based automotive supplier, which recently acquired leading edge ignition technology from EtaTech Inc. based in Florida (USA) has been involved in the development of sensor technology solutions that are individually tailored to suit their use in the vehicle. In case of the movement-measuring sensors, the distance sensor in particular, has found employment on Fiat’s 1.3 litre (Multijet) diesel engine with turbocharger, installed in the Grande Punto and the Fiat 500, among others. Based on a magneto-static principle and, in turbo chargers with variable turbine geometries, the distance sensor measures the setting of the pneumatic actuators that are responsible for adjusting the turbine blades to enable the boost pressure to be regulated. The new Beru distance sensors are, in fact, adjusted precisely to the turbocharger, which is supplied to Fiat by BorgWarner. They are calibrated not at the vehicle, but rather at the turbocharger itself. It means that automotive manufacturers do not need to carry out expensive calibration operations to the engine control unit.
Temperatures of up to 180 degrees Celsius and enormous mechanical loads place high demands on measuring elements and on the housings for new distance sensors. This is why Beru uses Duroplast for the housing. Duroplast is a plastic, which undergoes a hardening process to ensure that it will almost never deform. Its advantage includes low expansion and temperature co-efficients and thus good stability of form. Says Dipl. Ing. Ulrich Schneider, Product Manager for Sensors at BERU AG in Ludwigsburg, “However, Duroplasts are of extremely low viscosity and are processed on tools at up to 200 degrees Celsius”. “This situation sets maximum requirements for accuracy and density”, he adds. The structure of the sensor is based on a modular principle. This means that with a minor alteration, they can be applied without problems to other turbo chargers.
In the sensor product segment Beru provides its customers with comprehensive services from a single source. Explains Schneider, “We understand ourselves to be a development partner to the international automotive industry and automotive suppliers”. He elaborates, “It means that customers benefit from our experience covering more than 30 years in the sensor sector and from our enormous manufacturing expertise in the fields of metal processing and plastics engineering.” Concentrating on innovative sensor solutions for the power train and exhaust system, the Beru range of sensors includes temperature sensors for applications in diesel particle filters, oxidation catalytic converters, SCR systems, NOx storage cats and turbochargers such as the new Beru high temperature sensor HTS, for a measurement range of 40 to 950 degrees Celsius. Movement sensors such as speed sensors, distance and angle sensor. Smart sensors with intelligent electronics such as the radiator identification sensor (RIS).
In its sensor production facilities, Beru has access to a flexible combination of manufacturing and development at locations in Germany and in Ireland. Meeting new technical requirements, such as smaller engines and increased customer demands for an expansion of the testing facilities of new and innovative sensor products - necessary from the point of view of quality - at the same time reducing development times, Beru, at its Research and Development Centre (R&D) in Ludwigsburg offers its partners services from a single source. Right from the development and selection of material, covering high-performance prototype manufacturing through to testing on dedicated test benches, and to the electromagnetic compatibility specification (EMC) at the R&D Center.
Coming to Florida-based EtaTech Inc. and the area of high-frequency ignition technology enables high-performing, lean burning engines to significantly improve fuel economy and reduce emissions compared with conventional combustion technologies. Independent lab tests showed peak energy efficiency improved up to 40per cent, NOx emissions decreased 80per cent and CO2 emissions fell 50per cent. Current spark plug technology is unable to optimize high-performing, lean burning engines. Interestingly, the engineers at Ludwigsburg are working on the principle that will enable the manufacture of high-frequency ignition under series production within a few years.
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