Sensor and Actuator Technology in Engine Management (CarTrain)

In modern motor vehicles more and more components are being monitored and controlled electronically. Sensors have several jobs to do, including the detecting of physical data and converting this information into electrical signals which can then be processed by control units. Trainees should be able to grasp how this process works and the effects different sensor stimuli have on these signals.

List of Articles

CarTrain "Sensors, Open- and Closed-Loop Control Systems"

The subject of sensors is already a core subject of training in the area of service, repairs and diagnostics. The sensors in the motor vehicle are digitally networked and in recent years have taken on ever greater importance. The number of sensors inside the motor vehicle has also increased dramatically. How sensor signals are evaluated is also becoming more and more important in practical everyday diagnostics. The way sensors and actuators interact via open- and closed-loop controlled systems has also continued to become more complex. In this training system signals are recorded and evaluated using hands-on measuring and testing methods. Faults and malfunctions are diagnosed on vehicles based on customer complaints and by applying hands-on methods working with circuit diagrams and function diagrams. Measurements are performed using the integrated measurement interface and with the aid of all other suitable measuring instrument found in the repair shop.

Scope of supply:

• CarTrain “Sensors, open- and closed-loop control systems” (CO3221-6N)
• Integrated measurement interface
• Set of safety measurement leads
• Interactive course on CD-ROM with Labsoft browser, course software and additional virtual instruments

Virtual measuring instruments

• Digitally networked measuring option (WLAN-capable or using cables)
• 4-channel oscilloscope
• Voltmeter
• Ammeter
• Double voltmeter
• Power meter
• Function generator
• Pulse generator

Training contents:

• Investigate customer complaints, perform operation checks and establish diagnostics methods
• Read out fault memory
• Work safety
• Become familiar with where components are in the vehicle
• Determine faults and their causes with the aid of circuit diagrams and functional plans
• Create inspection record and document results
• Find out how data communication works between the component and the control unit
• Recognise what the repair options are
• Perform system measurements and tests
  • Determine the target data
  • Select appropriate measurement methods and instruments
  • Document measurement values
• Compile measurement values, compare these to target data and evaluate
• Measure signals to components and measure, test and evaluate systems
• Measure, test and evaluate electrical connections
• Design and function of pressure sensors
• Design and function of temperature sensors
• Design and function of air-quality sensors
• Advantages and disadvantages of individual sensor types
• Measurement options for recording the signals from various types of sensors in actual practice
• Measurement prerequisites for recording signals from various types of sensors in actual practice
• How sensors and actuators interact
• IPO principle
• Open-loop control processes in the motor vehicle
• Closed-loop control processes in the motor vehicle
• Difference between open- and closed-loop control

Components used in the experiment hardware:

• Fault simulation switches operational via WLAN
• Ignition switch
• Automotive fuses
• Intake manifold pressure sensor, frequency-controlled
• Intake manifold pressure sensor, analog for low-pressure and excess pressure measurements
• Intake manifold pressure sensor, analog with temperature detection
• Differential pressure sensor
• Air-quality sensor
• EGR valve with sensor and actuator
• Actuator motor with sensor and actuator
• E-gas throttle valve with sensors and actuator
• Knock sensor
• Temperature sensor for water cooler
• Temperature sensor for intake air temperature
• Temperature sensor for exhaust gas temperature
• Mass air-flow sensor PWM
• Mass air-flow meter, analog
• Electrically operated accelerator pedal with contactless sensors
• Control unit for connection to sensors and actuators
• Manometer for display of excess pressure and low-pressure levels
• Air connection terminal
• Automatic air-flow rate control for mass air-flow meter
• PWM generator for control system
• Automatic control of hardware components using measurement options
• 4-mm safety measurement plugs
• Connection slots for pull-up and pull-down resistors
• USB port
• 32 fault simulation options for diagnostics

Power supply:

• 100-240 V AC, 50-60 Hz

Operating voltage:

• 0 - 15 V DC

Dimensions:

• approx. 350 x 1010 x 805 (LxWxH in mm)

Additionally Required

Set of leads for "CarTrain: Sensors, open- & closed-loop control in vehicles"

This set of 4-mm connecting leads has been specially assembled for the "CarTrain: Sensors, open- & closed-loop control in vehicles" training system. To this end, the individual colours and the lengths of the leads are designed to support the educational aim of the training system, making it easier to wire up the sensors, actuators and power supply. Each of the measurement leads and jumpers features a special, protected design, whereby it is not possible to make contact with any current-carrying components. To make it possible to carry out measurements without difficulty, all the connector plugs include a tap socket. For each of the leads and jumpers included in the set, there is also a spare. In detail, the following components are included in the set:

Connecting leads

• 04 x Safety measurement leads (red, 100 cm)
• 03 x Safety measurement leads (black, 100 cm)
• 01 x Safety measurement leads (green, 100 cm)
• 04 x Safety measurement leads (yellow, 100 cm)

Measurement leads

• 02 x Safety measurement leads (red, 100 cm)
• 02 x Safety measurement leads (black, 100 cm)

Over-/Under Pressure Pump

Manual pump for monitoring and setting under-pressure or over-pressure functions. Quick and easy to use. Integrated discharge valve for reducing the under-pressure or over-pressure, without removing the terminal connections. With a connection hose and a variety of end pieces.

• Under-pressure: -1000....+1000mbar
• Weight: 0.4kg

Accessories

SybaPro Mobile InsTrain/CarTrain Experiment Trolley, 1070x1350x700mm

The mobile aluminium-profile experiment trolley is specially designed to accommodate components of the InsTrain and CarTrain system. All the Ins-Train and CarTrain system components can be safely mounted in structured fashion for lessons from the front of a class or for students' own practicals. For students, this provides a modern, educationally designed workplace with a worktop and connections for multimedia.

• The mobile experiment stand is delivered in kit form and needs to be assembled by the customer
• Aluminium profile with integrated grooves for attaching a wide variety of components (e.g. PC and monitor-holders)
• 4 steerable double casters, 2 with brakes
• Worktop 1000 x 30 x 700 mm (WxHxD)
• Table top made of highly compressed multilayered chipboard conforming to DIN EN 438-1, light grey, with double-sided 0.8 mm slightly textured laminate coating (Resopal) in compliance with DIN 16926
• Table top bordered with solid, impact-resistant edging made of 3-mm thick plastic, colour RAL 7047
• Coating and adhesives must be PVC-free
• Power strip with 5-outlet sockets and power switch, lead and earthed plug
• Height of table top 830 mm
• Dimensions without CarTrain/InsTrain-System: 1070 x 1350 x 700 (WxHxD)
• Dimensions with CarTrain/InsTrain-System: 1070 x 1650 x 700 (WxHxD)

PC Holder for SybaPro Experiment Trolleys, Height/Width Adjustable

Shelf for desktop PC made of 2 mm sheet steel punched with holes, suitable for all furniture in the SybaPro aluminium profile range

• Adjustable assembly height
• for slim PCs, adjustable width (60 - 160 mm)
• with fastening and rubber stopper
• Can be mounted to left or right
• Includes all equipment necessary for assembly (4 bolts and 4 tenon blocks)
• Acid-resistant epoxy-resin powder coating, 80 µm thick approx., colour RAL7047

Under-Table Cabinet, Suspended, 4 Drawers, Central Locking

• 1 Utensil drawer
• 1 Drawer, 2 HU
• 2 Drawers, 4 HU
• Usable width: 330mm, usable depth: 480 mm
• Central locking
• Metal drawers with surrounding row of slots
• Body made of 19 mm-thick, highly-compressed, multi-layered fine chipboard with grade E1 plastic coating on both sides
• Dimensions: 430 x 580 x 590 mm (WxDxH)